Semiconductor device

ABSTRACT

A highly reliable semiconductor device including an oxide semiconductor is provided. Provided is a semiconductor device including an oxide semiconductor layer, an insulating layer in contact with the oxide semiconductor layer, a gate electrode layer overlapping with the oxide semiconductor layer, and a source electrode layer and a drain electrode layer electrically connected to the oxide semiconductor layer. The oxide semiconductor layer includes a first region having a crystal whose size is less than or equal to 10 nm and a second region which overlaps with the insulating layer with the first region provided therebetween and which includes a crystal part whose c-axis is aligned in a direction parallel to a normal vector of the surface of the oxide semiconductor layer.

TECHNICAL FIELD

The present invention disclosed in this specification relates to anobject, a method, a manufacturing method, a process, a machine,manufacture, or a composition of matter. In particular, the presentinvention relates to, for example, a semiconductor device, a displaydevice, a light-emitting device, a power storage device, a drivingmethod thereof, or a manufacturing method thereof. For example, thepresent invention relates to a semiconductor device including an oxidesemiconductor, a display device including an oxide semiconductor, or alight-emitting device including an oxide semiconductor.

In this specification and the like, a “semiconductor device” generallyrefers to a device which can function by utilizing semiconductorcharacteristics: an electro-optical device, a semiconductor circuit, adisplay device, a light-emitting device, and an electronic device areall included in the category of the semiconductor device.

BACKGROUND ART

A technique by which a transistor is formed using a semiconductor filmformed over a substrate having an insulating surface has been attractingattention. The transistor is applied to a wide range of electronicdevices such as an integrated circuit (IC) and an image display device(also simply referred to as display device). As a semiconductor filmapplicable to the transistor, a silicon-based semiconductor material iswidely known; moreover, a metal oxide exhibiting semiconductorcharacteristics (an oxide semiconductor) has been attracting attentionas another material.

For example, Patent Document 1 discloses a technique in which atransistor is manufactured using an amorphous oxide containing In, Zn,Ga, Sn, and the like as an oxide semiconductor.

Although a transistor including an oxide semiconductor film can obtaintransistor characteristics relatively with ease, the oxide semiconductorfilm is likely to be amorphous and has unstable physical properties.Thus, it is difficult to secure reliability of such a transistor.

On the other hand, there is a report that a transistor including acrystalline oxide semiconductor film has more excellent electricalcharacteristics and higher reliability than a transistor including anamorphous oxide semiconductor film (see Non-Patent Document 1).

REFERENCE Patent Document

-   [Patent Document 1] Japanese Published Patent Application No.    2006-165529

Non-Patent Document

-   [Non-Patent Document 1] Shunpei Yamazaki, Jun Koyama, Yoshitaka    Yamamoto, and Kenji Okamoto, “Research, Development, and Application    of Crystalline Oxide Semiconductor”, SID 2012 DIGEST, pp. 183-186

DISCLOSURE OF INVENTION

An object of one embodiment of the present invention is to provide ahighly reliable semiconductor device including an oxide semiconductor.

Another object of one embodiment of the present invention is to providea transistor or the like having a low off-state current. Another objectof one embodiment of the present invention is to provide a transistor orthe like having normally-off characteristics. Another object of oneembodiment of the present invention is to provide a transistor or thelike whose threshold voltage is less likely to vary or deteriorate.Another object of one embodiment of the present invention is to providea semiconductor device or the like with low power consumption. Anotherobject of one embodiment of the present invention is to provide aneye-friendly display device or the like. Another object of oneembodiment of the present invention is to provide a semiconductor deviceor the like including a transparent semiconductor layer. Another objectof one embodiment of the present invention is to provide a novelsemiconductor device or the like.

Note that the descriptions of these objects do not disturb the existenceof other objects. Note that one embodiment of the present invention doesnot necessarily achieve all the objects. Other objects will be apparentfrom and can be derived from the description of the specification, thedrawings, the claims, and the like.

One embodiment of the disclosed invention is a semiconductor deviceincluding an oxide semiconductor layer and an insulating layer incontact with the oxide semiconductor layer. The oxide semiconductorlayer includes a first region having a crystal whose size is less thanor equal to 10 nm and a second region which overlaps with the insulatinglayer with the first region provided therebetween and which includes acrystal part whose c-axis is aligned in a direction parallel to a normalvector of the surface of the oxide semiconductor layer. Specifically,one embodiment of the disclosed invention is, for example, asemiconductor device having any of the following structures.

One embodiment of the present invention is a semiconductor deviceincluding an oxide semiconductor layer, an insulating layer in contactwith the oxide semiconductor layer, a gate electrode layer overlappingwith the oxide semiconductor layer, and a source electrode layer and adrain electrode layer electrically connected to the oxide semiconductorlayer. The oxide semiconductor layer includes a first region having acrystal whose size is less than or equal to 10 nm and a second regionwhich overlaps with the insulating layer with the first region providedtherebetween and which includes a crystal part whose c-axis is alignedin a direction parallel to a normal vector of the surface of the oxidesemiconductor layer.

In the above semiconductor device, oxide semiconductors included in thefirst region and the second region may have different compositions.

Another embodiment of the present invention is a semiconductor deviceincluding a first insulating layer, an oxide semiconductor layer overthe first insulating layer, a second insulating layer over the oxidesemiconductor layer, a gate electrode layer overlapping with the oxidesemiconductor layer, and a source electrode layer and a drain electrodelayer electrically connected to the oxide semiconductor layer. The oxidesemiconductor layer includes a first region having a crystal whose sizeis less than or equal to 10 nm, a second region which overlaps with thefirst insulating layer with the first region provided therebetween andwhich includes a crystal part whose c-axis is aligned in a directionparallel to a normal vector of the surface of the oxide semiconductorlayer, and a third region which is located between the second region andthe second insulating layer and which has a crystal whose size is lessthan or equal to 10 nm.

In the above semiconductor device, oxide semiconductors included in thefirst region and the second region may have different compositions, andoxide semiconductors included in the second region and the third regionmay have different compositions.

In the above semiconductor device, in the third region, in some cases, aplurality of circumferentially distributed spots are observed bynanobeam electron diffraction in which a diameter of an electron beam isreduced to 1 nmφ or more and 10 nmφ or less, and a halo pattern isobserved by selected-area electron diffraction using a transmissionelectron microscope where a diameter of an electron beam is 300 nmφ ormore.

Further, in the above semiconductor device, in the first region, in somecases, a plurality of circumferentially distributed spots are observedby nanobeam electron diffraction in which a diameter of an electron beamis reduced to 1 nmφ or more and 10 nmφ or less, and a halo pattern isobserved by selected-area electron diffraction using a transmissionelectron microscope where a diameter of an electron beam is 300 nmφ orless.

Moreover, in the above semiconductor device, a film density of thesecond region is preferably higher than a film density of the firstregion.

In the above semiconductor device, a channel is preferably formed in thesecond region.

In accordance with one embodiment of the present invention, a highlyreliable semiconductor device can be provided.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A to 1C are schematic views each exemplifying a stacked-layerstructure of a semiconductor device of one embodiment of the presentinvention.

FIGS. 2A and 2B are schematic views illustrating sputtered particlesseparated from a sputtering target.

FIGS. 3A, 3B1 and 3B2, and 3C are diagrams describing a discharge statewhen sputtering is performed using an AC power source.

FIG. 4 is a schematic diagram illustrating a state in which sputteredparticles reach a deposition surface at the substrate heating.

FIG. 5 is a schematic diagram illustrating a state in which sputteredparticles reach a deposition surface at the deposition at roomtemperature.

FIGS. 6A and 6B each illustrate a crystal structure of an oxidesemiconductor of one embodiment of the present invention.

FIGS. 7A and 7B are flow charts exemplifying a method for manufacturinga sputtering target.

FIGS. 8A and 8B are a schematic view exemplifying a stacked-layerstructure of a semiconductor device of one embodiment of the presentinvention and a band structure thereof.

FIGS. 9A to 9C each illustrate a structure example of a transistor ofone embodiment.

FIGS. 10A to 10D illustrate an example of a method for manufacturing atransistor of one embodiment.

FIGS. 11A and 11B each illustrate a structure example of a transistor ofone embodiment.

FIGS. 12A and 12B are circuit diagrams each illustrating a semiconductordevice of one embodiment of the present invention.

FIGS. 13A to 13C are circuit diagrams and a conceptual diagram of asemiconductor device of one embodiment of the present invention.

FIGS. 14A to 14C illustrate a structure of a display panel of oneembodiment.

FIG. 15 is a block diagram of an electronic device of one embodiment.

FIGS. 16A to 16D are each an external view of an electronic device ofone embodiment.

FIGS. 17A to 17D show a cross-sectional TEM image and nanobeam electrondiffraction patterns of a nanocrystalline oxide semiconductor layer.

FIGS. 18A and 18B show a plane TEM image and a selected-area electrondiffraction pattern of a nanocrystalline oxide semiconductor layer.

FIGS. 19A to 19C are conceptual diagrams of electron diffractionintensity distribution.

FIG. 20 shows a nanobeam electron diffraction pattern of a quartz glasssubstrate.

FIG. 21 shows a nanobeam electron diffraction pattern of ananocrystalline oxide semiconductor layer.

FIGS. 22A and 22B show cross-sectional TEM images of a nanocrystallineoxide semiconductor layer.

FIG. 23 shows the result of X-ray diffraction analysis of ananocrystalline oxide semiconductor layer.

FIG. 24 shows a crystal structure of an oxide semiconductor layer usedfor calculation.

FIGS. 25A to 25D show the calculation results of an influence ofhydrogen addition on a crystal state.

FIG. 26 shows the calculation result of a radial distribution function.

FIGS. 27A to 27C show nanobeam electron diffraction patterns of an oxidesemiconductor layer obtained with a nanobeam electron beam.

FIG. 28 shows the result of CPM measurement performed on an oxidesemiconductor layer.

FIGS. 29A and 29B each show the result of CPM measurement performed onan oxide semiconductor layer.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments and examples of the present invention are described indetail below with reference to the accompanying drawings. However, thepresent invention is not limited to the description below, and it iseasily understood by those skilled in the art that modes and aspectsthereof can be modified in various ways. Therefore, the presentinvention is not construed as being limited to description of theembodiments and examples.

Note that in each drawing described in this specification, the size, thefilm thickness, or the region of each component is exaggerated forclarity in some cases. Therefore, the scale is not necessarily limitedto that illustrated in the drawings.

Note that the ordinal numbers such as “first” and “second” in thisspecification and the like are used for convenience and do not denotethe order of steps, the stacking order of layers, or the like. Inaddition, the ordinal numbers in this specification and the like do notdenote particular names which specify the present invention.

In this specification and the like, a term “parallel” indicates that theangle formed between two straight lines is greater than or equal to −10°and less than or equal to 10°, and accordingly also includes the casewhere the angle is greater than or equal to −5° and less than or equalto 5°. In addition, a term “perpendicular” indicates that the angleformed between two straight lines is greater than or equal to 80° andless than or equal to 100°, and accordingly includes the case where theangle is greater than or equal to 85° and less than or equal to 95°.

In this specification and the like, the trigonal and rhombohedralcrystal systems are included in the hexagonal crystal system.

Embodiment 1

In this embodiment, an oxide semiconductor layer included in asemiconductor device of one embodiment of the present invention will bedescribed with reference to FIGS. 1A to 1C.

<Stacked-Layer Structure of Oxide Semiconductor Layer>

FIG. 1A is a schematic view exemplifying a stacked-layer structure of asemiconductor device of one embodiment of the present invention. Thesemiconductor device of one embodiment of the present invention includesan oxide semiconductor layer 104 in contact with a top surface of aninsulating layer 102.

The oxide semiconductor layer 104 includes a first region 104 a and asecond region 104 b overlapping with the insulating layer 102 with thefirst region 104 a provided therebetween.

In the oxide semiconductor layer 104, both the first region 104 a andthe second region 104 b are crystalline regions and have differentcrystallinity. Specifically, crystallinity of the second region 104 b ishigher than that of the first region 104 a.

As a crystalline oxide semiconductor, for example, a single crystaloxide semiconductor, a c-axis aligned crystalline oxide semiconductor(CAAC-OS), an oxide semiconductor including a polycrystal (hereinafterreferred to as a polycrystalline oxide semiconductor), and an oxidesemiconductor including a microcrystal (also referred to as ananocrystal) (hereinafter referred to as a nanocrsytalline oxidesemiconductor) can be given.

In the oxide semiconductor layer 104 of this embodiment, the firstregion 104 a preferably includes a crystal (nanocrystal (nc)) whose sizeis greater than or equal to 1 nm and less than or equal to 10 nm, forexample.

The nanocrystalline oxide semiconductor film is a dense film whose filmdensity is higher than that of an amorphous oxide semiconductor film.Thus, in the oxide semiconductor layer 104, the density of defect statesof the first region 104 a including a nanocrystal is lower than that ofan amorphous oxide semiconductor film.

Note that in this specification, an amorphous oxide semiconductor filmhas disordered atomic arrangement and no crystalline component. Atypical example thereof is an oxide semiconductor film in which nocrystal part exists even in a microscopic region, and the whole of thefilm is amorphous.

The second region 104 b preferably includes a crystal part whose c-axisis aligned in a direction parallel to a normal vector of a surface overwhich the oxide semiconductor layer 104 is formed or a normal vector ofa surface of the oxide semiconductor layer 104. An example of such anoxide semiconductor film is a CAAC-OS film.

The CAAC-OS film is one of oxide semiconductor films including aplurality of crystal parts, and most of the crystal parts each fitinside a cube whose one side is less than 100 nm. Thus, there is a casewhere a crystal part included in the CAAC-OS film fits inside a cubewhose one side is less than 10 nm, less than 5 nm, or less than 3 nm. Ina transmission electron microscope (TEM) image of the CAAC-OS film, aboundary between crystal parts, that is, a grain boundary is not clearlyobserved. Thus, in the CAAC-OS film, a reduction in electron mobilitydue to the grain boundary is less likely to occur.

According to the TEM image of the CAAC-OS film observed in a directionsubstantially parallel to a sample surface (cross-sectional TEM image),metal atoms are arranged in a layered manner in the crystal parts. Eachmetal atom layer has a morphology reflected by a surface over which theCAAC-OS film is formed (hereinafter a surface over which the CAAC-OSfilm is formed is referred to as a formation surface) or a top surfaceof the CAAC-OS film, and is arranged in parallel to the formationsurface or the top surface of the CAAC-OS film.

On the other hand, according to the TEM image of the CAAC-OS filmobserved in a direction substantially perpendicular to the samplesurface (plan TEM image), metal atoms are arranged in a triangular orhexagonal configuration in the crystal parts. However, there is noregularity of arrangement of metal atoms between different crystalparts.

From the results of the cross-sectional TEM image and the plan TEMimage, alignment is found in the crystal parts in the CAAC-OS film.

A CAAC-OS film is subjected to structural analysis with an X-raydiffraction (XRD) apparatus. For example, when the CAAC-OS filmincluding an InGaZnO₄ crystal is analyzed by an out-of-plane method, apeak appears frequently when the diffraction angle (2θ) is around 31°.This peak is derived from the (009) plane of the InGaZnO₄ crystal, whichindicates that crystals in the CAAC-OS film have c-axis alignment, andthat the c-axes are aligned in a direction substantially perpendicularto the formation surface or the top surface of the CAAC-OS film.

On the other hand, when the CAAC-OS film is analyzed by an in-planemethod in which an X-ray enters a sample in a direction substantiallyperpendicular to the c-axis, a peak appears frequently when 2θ is around56°. This peak is derived from the (110) plane of the InGaZnO₄ crystal.Here, analysis (φ scan) is performed under conditions where the sampleis rotated around a normal vector of a sample surface as an axis (φaxis) with 2θ fixed at around 56°. In the case where the sample is asingle crystal oxide semiconductor film of InGaZnO₄, six peaks appear.The six peaks are derived from crystal planes equivalent to the (110)plane. On the other hand, in the case of a CAAC-OS film, a peak is notclearly observed even when 0 scan is performed with 28 fixed at around56°.

According to the above results, in the CAAC-OS film having c-axisalignment, while the directions of a-axes and b-axes are differentbetween crystal parts, the c-axes are aligned in a direction parallel toa normal vector of a formation surface or a normal vector of a topsurface. Thus, each metal atom layer arranged in a layered mannerobserved in the cross-sectional TEM image corresponds to a planeparallel to the a-b plane of the crystal.

Note that the crystal part is formed concurrently with deposition of theCAAC-OS film or is formed through crystallization treatment such as heattreatment. As described above, the c-axis of the crystal is aligned witha direction parallel to a normal vector of a formation surface or anormal vector of a top surface. Thus, for example, in the case where ashape of the CAAC-OS film is changed by etching or the like, the c-axismight not be necessarily parallel to a normal vector of a formationsurface or a normal vector of a top surface of the CAAC-OS film.

Further, the degree of crystallinity in the CAAC-OS film is notnecessarily uniform. For example, in the case where crystal growthleading to the CAAC-OS film occurs from the vicinity of the top surfaceof the film, the degree of the crystallinity in the vicinity of the topsurface is in some cases higher than that in the vicinity of theformation surface. Further, when an impurity is added to the CAAC-OSfilm, the crystallinity in a region to which the impurity is added ischanged, and the degree of crystallinity in the CAAC-OS film variesdepending on regions.

Note that when the CAAC-OS film with an InGaZnO₄ crystal is analyzed byan out-of-plane method, a peak of 2θ may also be observed at around 36°,in addition to the peak of 2θ at around 31°. The peak of 2θ at around36° indicates that a crystal having no c-axis alignment is included inpart of the CAAC-OS film. It is preferable that in the CAAC-OS film, apeak of 2θ appear at around 31° and a peak of 2θ do not appear at around36°.

The CAAC-OS film is a dense film whose film density is much higher thanthat of a nanocrystalline oxide semiconductor film. Thus, in the oxidesemiconductor layer 104, the density of defect states of the secondregion 104 b including a CAAC-OS is lower than that of the first region104 a including a nanocrystal.

The oxide semiconductor layer 104 shown in this embodiment includes thefirst region 104 a including a nanocrystal which is an oxidesemiconductor in which defect state density is reduced, and the secondregion 104 b including a CAAC-OS which is an oxide semiconductor inwhich density of defect states is much lower than that of ananocrystalline oxide semiconductor.

In a semiconductor device including an oxide semiconductor layer, it isnecessary to reduce defect states of the oxide semiconductor layer thatfunctions as a channel and the interface thereof so that the reliabilitycan be improved. In a transistor including an oxide semiconductor layer,a shift of threshold voltage in the negative direction occursparticularly because of defect states due to oxygen vacancies in theoxide semiconductor layer that functions as a channel and oxygenvacancies in the interface thereof.

Thus, with the use of the oxide semiconductor layer 104 including aregion in which defects states are reduced for a transistor as shown inthis embodiment, a change in electrical characteristics of thetransistor due to irradiation of visible light or ultraviolet light canbe suppressed. Therefore, the reliability of the transistor can beimproved.

In the case where the oxide semiconductor layer 104 is used for atransistor, it is preferable to use the second region 104 b including aCAAC-OS in which defect states are further reduced for a main currentpath (channel) of the transistor. Moreover, in the case where the secondregion 104 b functions as a main current path of the transistor, thestructure in which the first region 104 a is provided at the interfacebetween the insulating layer 102 and the second region 104 b has aneffect of suppressing formation of a defect state at the interfacebetween the channel and the insulating layer 102.

Further, even when the second region 104 b functions as a main currentpath in the oxide semiconductor layer 104, a certain amount of currentsometimes flows also in the first region 104 a. Since the first region104 a of the oxide semiconductor layer 104 shown in this embodiment alsoincludes a nanocrystalline oxide semiconductor in which defect statedensity is lower, the reliability can be improved as compared to thecase where the first region 104 a includes an amorphous oxidesemiconductor.

Note that a stacked-layer structure of the semiconductor device of oneembodiment of the present invention is not limited to the structure ofFIG. 1A. For example, a structure in which an insulating layer 106 isprovided over an oxide semiconductor layer 114 as illustrated in FIG. 1Bmay be employed.

In FIG. 1B, the oxide semiconductor layer 114 under the insulating layer106 includes a first region 114 a including a nanocrystal over a secondregion 114 b including a CAAC-OS. In other words, in FIG. 1B, the oxidesemiconductor layer 114 includes the first region 114 a and the secondregion 114 b overlapping with the insulating layer 106 with the firstregion 114 a provided therebetween in a manner similar to that of FIG.1A.

Alternatively, as illustrated in FIG. 1C, a structure including an oxidesemiconductor layer 124 over the insulating layer 102 and the insulatinglayer 106 over the oxide semiconductor layer 124 may have astacked-layer structure in which the oxide semiconductor layer 124includes a first region 124 a including a nanocrystal, a second region124 b overlapping with the insulating layer 102 with the first region124 a provided therebetween and including a CAAC-OS, and a third region124 c being located between the second region 124 b and the insulatinglayer 106 and including a nanocrystal.

The oxide semiconductor layer 114 in FIG. 1B and the oxide semiconductorlayer 124 in FIG. 1C as well as the oxide semiconductor layer 104 inFIG. 1A are each an oxide semiconductor layer which includes a regionincluding a nanocrystal and a region including a CAAC-OS and in whichdefect states are reduced. Thus, with the use of such an oxidesemiconductor layer for a transistor, a highly reliable transistor inwhich a change in electrical characteristics is suppressed can beprovided.

Further, as well as the stacked-layer structure in FIG. 1A, thestacked-layer structure in FIG. 1B includes the first region 114 aincluding a nanocrystal provided between the second region 114 bincluding a CAAC-OS and the insulating layer 106. Similarly, thestacked-layer structure in FIG. 1C includes the first region 124 aincluding a nanocrystal provided between the second region 124 bincluding a CAAC-OS and the insulating layer 102 and the third region124 c including a nanocrystal provided between the second region 124 bincluding a CAAC-OS and the insulating layer 106. With such structures,in the case where the second region 114 b functions as a channel in atransistor including the oxide semiconductor layer 114, direct contactbetween the channel and the insulating layer 106 in contact with theoxide semiconductor layer 114 can be suppressed; and in the case wherethe second region 124 b functions as a channel in a transistor includingthe oxide semiconductor layer 124, direct contact between the channeland the insulating layer 106 or the insulating layer 102 in contact withthe oxide semiconductor layer 124 can be suppressed. Accordingly, ineach case, a defect state can be prevented from being formed at theinterface of the channel. Thus, the reliability of the transistors canbe improved.

Note that the oxide semiconductor layers 104, 114, and 124 illustratedin FIGS. 1A, 1B, and 1C, respectively, may each include a single crystalregion or an amorphous region.

For example, in FIG. 1A, the oxide semiconductor layer 104 may includean amorphous region over the second region 104 b. Alternatively, in FIG.1B, the oxide semiconductor layer 114 may include an amorphous regionunder the second region 114 b.

The first region 104 a and the second region 104 b included in the oxidesemiconductor layer 104 in FIG. 1A may each have a structure in which asingle-layer film includes regions having different crystallinity or astructure in which films having different crystallinity are stacked. Inother words, in this specification and the like, a term “region” can bealternatively referred to as a “layer” unless otherwise described. Forexample, the oxide semiconductor layer 104 may have a stacked-layerstructure of a first oxide semiconductor layer including a nanocrystaland a second oxide semiconductor layer including a CAAC-OS.

Note that in the case where the oxide semiconductor layer 104 has astacked-layer structure of the first oxide semiconductor layer includinga nanocrystal and the second oxide semiconductor layer including aCAAC-OS, metal elements included in the first oxide semiconductor layerand the second oxide semiconductor layer may be the same or different.Alternatively, in the case where the same metal elements are included,the compositions thereof may be the same or different. The same appliesto the oxide semiconductor layer 114 and the oxide semiconductor layer124.

The oxide semiconductor layers shown in this embodiment each include aregion including a nanocrystal at the interface between an insulatinglayer and a region including a CAAC-OS that functions as a main currentpath. Thus, the reliability of the transistors including the oxidesemiconductor layers can be improved.

Note that although the oxide semiconductor layers shown in thisembodiment can be each included in, for example, an active layer of thetransistor, an embodiment of the present invention is not limited tosuch use. The oxide semiconductor layer shown in this embodiment can beincluded as some of various elements. For example, the oxidesemiconductor layer shown in this embodiment can be included as part ofa resistor. The resistor can be included in a protection circuit.Alternatively, for example, the oxide semiconductor layer shown in thisembodiment can be included as part of an electrode of a capacitor. Thecapacitor can be included as a storage capacitor in a pixel or acapacitor in a driver circuit. In the case where the oxide semiconductorlayer shown in this embodiment is included in a transistor, a capacitor,or a resistor, other oxide semiconductor layers included in theseelements may be formed at the same time. Such a case is preferablebecause the number of process steps can be reduced. Note that in thecase where the oxide semiconductor layer shown in this embodiment isincluded in a capacitor or a resistor, hydrogen or the like can beintroduced into the film to lower the resistance value. Accordingly, theresistance value of the oxide semiconductor layer shown in thisembodiment can be lowered in such a manner that a film containinghydrogen, such as a silicon nitride film, is made in contact with theoxide semiconductor layer shown in this embodiment.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 2

In this embodiment, film formation of a crystal part included in theoxide semiconductor layer described in Embodiment 1 will be describedwith reference to

FIGS. 2A and 2B, FIGS. 3A to 3C, FIG. 4, FIG. 5, and FIGS. 6A and 6B.Note that the following model is just a consideration, and an embodimentof the present invention is not limited thereto.

<Film Formation Model of Crystal Part>

FIG. 2A is a schematic view illustrating a state in which an ion 1001collides with a sputtering target 1000 to separate sputtered particles1002 from the sputtering target 1000 at the deposition of the oxidesemiconductor layer. FIGS. 2A and 2B illustrate the case where thesputtered particle 1002 has the shape of a hexagonal cylinder whosehexagonal planes are parallel to an a-b plane or the case where thesputtered particle 1002 has the shape of a triangular prism whosetriangular planes are parallel to an a-b plane. In the case where thesputtered particle 1002 has the shape of the hexagonal cylinder, thedirection perpendicular to the hexagonal planes is a c-axis direction(see FIG. 2B). Note that the same applies to the case of the shape of atriangular prism. The diameter (equivalent circle diameter) of the planeof the sputtered particle 1002 which is parallel to the a-b plane isapproximately greater than or equal to 1 nm and less than or equal to 30nm or greater than or equal to 1 nm and less than or equal to 10 nm,though it differs depending on the kind of oxide semiconductor to beused. Note that an oxygen cation is used as the ion 1001. An argoncation may be used in addition to the oxygen cation. Note that a cationof another rare gas may be used instead of an argon cation.

With the use of an oxygen cation as the ion 1001, plasma damage at thedeposition can be alleviated. Thus, when the ion 1001 collides with thesurface of the sputtering target 1000, a lowering in crystallinity ofthe sputtering target 1000 can be suppressed or a change of thesputtering target 1000 into an amorphous state can be suppressed.

It is preferable that the separated sputtered particles 1002 bepositively charged. However, there is no particular limitation on thetiming at which the sputtered particles 1002 are positively charged.Specifically, the sputtered particle 1002 is in some cases positivelycharged by being exposed to plasma. Alternatively, the sputteredparticle 1002 is in some cases positively charged by receiving anelectric charge at the collision of the ion 1001. Further alternatively,the sputtered particle 1002 is in some cases positively charged in sucha manner that the ion 1001 which is an oxygen cation is bonded to aside, top, or bottom surface of the sputtered particle 1002.

In the sputtered particle 1002, the corners of the polygonal plane arepositively charged, whereby positive charges of the hexagonal planerepel each other. Thus, flat-plate shapes of the sputtered particles1002 can be maintained.

It is preferable to use a direct-current (DC) power source to positivelycharge the corners of the polygonal plane of the sputtered particle1002. Note that a radio frequency (RF) power source or analternating-current (AC) power source can also be used. Note that it isdifficult to use an RF power source for a sputtering apparatus which iscapable of performing deposition to a large-sized substrate. Inaddition, a DC power source is preferred to an AC power source from theviewpoint below.

In the AC power source, adjacent targets alternately have a cathodepotential and an anode potential. In a period A shown in FIG. 3A, atarget 1 functions as a cathode and a target 2 functions as an anode asillustrated in FIG. 3B1. In a period B shown in FIG. 3A, the target 1functions as an anode and the target 2 functions as a cathode asillustrated in FIG. 3B2. The total time of the period A and the period Bis 20 microseconds to 50 microseconds and the period A and the period Bare repeated at a constant frequency.

In the case where the sputtered particle 1002 is positively charged,positive charges in the sputtered particle 1002 repel each other,whereby flat-plate shapes of the sputtered particles 1002 can bemaintained. However, in the case where the AC power source is used,there is time during which an electric field is not appliedinstantaneously; therefore, some charges of the sputtered particle 1002are lost and the structure of the sputtered particle might be broken(see FIG. 3C). Thus, a DC power source is preferred to an AC powersource.

<<Deposition of CAAC-OS>>

A state in which sputtered particles are deposited on a depositionsurface is described below with reference to FIG. 4. Note that FIG. 4illustrates the case where deposition is performed in the sate where asubstrate is heated.

As illustrated in FIG. 4, in the case of substrate heating, onesputtered particle 1002 moves to a region of a deposition surface 1003where other sputtered particles 1002 have not been deposited yet andmigration of the sputtered particle 1002 occurs, whereby the sputteredparticle 1002 is bonded to the side of the sputtered particles which arealready deposited. In this manner, the sputtered particles 1002 arespread with flat plate planes facing upward. The c-axes of the depositedsputtered particles 1002 are aligned in one direction perpendicular tothe deposition surface 1003; accordingly, a CAAC-OS film is obtained.Moreover, an oxide semiconductor layer having a uniform thickness and auniform crystal orientation is formed with an oxide film obtained by thedeposition.

The CAAC-OS film obtained by such a mechanism has high crystallinityeven on an amorphous surface, an amorphous insulating surface, a surfaceof an amorphous oxide film, or the like.

<<Deposition of Nanocrystalline Oxide Semiconductor>>

FIG. 5 illustrates a state in which sputtered particles are deposited ona deposition surface in the case where deposition is performed withoutsubstrate heating.

According to FIG. 5, in the case without substrate heating (e.g., thecase where the substrate temperature is room temperature±50° C.,preferably room temperature±10° C.), the sputtered particles 1002 fallirregularly to the deposition surface 1003. Thus, the sputteredparticles 1002 are deposited randomly also in a region where othersputtered particles 1002 are already deposited. That is, an oxidesemiconductor layer obtained by the deposition has neither a uniformthickness nor a uniform crystal orientation. The oxide semiconductorlayer obtained in such a manner is an oxide semiconductor layerincluding a crystal part because the crystallinity of flat plate-likesputtered particles 1002 is maintained to some extent.

As described above, the diameter of the plane of the sputtered particle1002 which is parallel to the a-b plane is, for example, approximatelygreater than or equal to 1 nm and less than or equal to 30 nm or greaterthan or equal to 1 nm and less than or equal to 10 nm, and a crystalpart included in the deposited oxide semiconductor layer is smaller thanthe sputtered particle 1002 in some cases. The oxide semiconductor layerincludes a crystal part with a size of, for example, 10 nm or less or 5nm or less in some cases, which is a nanocrystalline oxide semiconductorlayer.

The nanocrystalline oxide semiconductor layer is macroscopicallyequivalent to a film having disordered atomic arrangement. For thisreason, in some cases, a peak indicating an orientation is not observedin X-ray diffraction (XRD) analysis which is performed on a large areaof a measurement sample (for example, in which the beam diameter islarger than that of the sputtered particle 1002). Further, in somecases, an electron diffraction pattern obtained by using an electronbeam with a diameter larger than that of the sputtered particle 1002 isa halo pattern. In this case, for example, a nanocrystalline oxidesemiconductor layer is measured with an electron beam having a beamdiameter much smaller than the sputtered particle 1002, whereby a spot(bright spot) can be observed in the obtained nanobeam electrondiffraction pattern.

Note that the deposition surface 1003 preferably has an insulatingproperty. With the deposition surface 1003 having an insulatingproperty, the sputtered particles 1002 which are deposited on thedeposition surface 1003 are less likely to lose positive charges.However, in the case where the deposition rate of the sputteredparticles 1002 is less than the rate at which a positive charge is lost,the deposition surface 1003 may have conductivity. Note that thedeposition surface 1003 is preferably an amorphous surface or anamorphous insulating surface.

FIG. 6A illustrates a crystal structure of an In—Ga—Zn oxide viewed froma direction parallel to an a-b plane of the crystal. FIG. 6B illustratesthe crystal structure after ion collision during sputtering.

For example, cleavage of the crystal included in the In—Ga—Zn oxideoccurs between a layer including a gallium atom and/or zinc atom and anoxygen atom, and a layer including a gallium atom and/or zinc atom andan oxygen atom, which are illustrated in FIG. 6B. This is because oxygenatoms which have negative charges exist in the layer in a close distancefrom each other. In this manner, the cleavage plane is parallel to thea-b plane.

That is, when an ion collides with the surface of a sputtering targetincluding a crystal grain of an In—Ga—Zn oxide, the crystal included inthe In—Ga—Zn oxide is cleaved along a plane parallel to the a-b plane ofthe crystal, and flat plate-like sputtered particles whose top andbottom surfaces are parallel to the a-b plane are separated from thesputtering target.

Moreover, in the crystal of the In—Ga—Zn oxide illustrated in FIGS. 6Aand 6B, metal atoms are arranged in a regular triangular or regularhexagonal configuration when seen from the direction perpendicular tothe a-b plane; therefore, the flat plate-like crystal grain is likely tohave the shape of a hexagonal cylinder whose regular hexagonal plane hasinternal angles of 120°.

<Method for Manufacturing Sputtering Target>

A method for manufacturing the above sputtering target is described withreference to FIGS. 7A and 7B.

In FIG. 7A, an oxide powder containing a plurality of metal elementswhich is used for the sputtering target is manufactured. First, theoxide powder is weighed in a step S101.

Here, description is given on the case where an oxide powder containingIn, M, and Zn (also referred to as an In-M-Zn oxide powder) is obtainedas the oxide powder containing a plurality of metal elements.Specifically, an InO_(x) oxide powder, an MO_(Y) oxide powder, and aZnO_(z) oxide powder are prepared as a raw material. Note that X, Y, andZ are each a given positive number; for example, X, Y, and Z are 1.5,1.5, and 1, respectively. It is needless to say that the above oxidepowders are examples, and oxide powders can be selected as appropriatein order to obtain a desired composition. Note that M refers to Ga, Sn,Hf, Al, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, or Lu.Although the case where three kinds of oxide powders are used is shownas an example in this embodiment, one embodiment of the presentinvention is not limited thereto. For example, this embodiment may beapplied to the case where four or more kinds of oxide powders are usedor the case where one or two kinds of oxide powders are used.

Next, the InO_(X) oxide powder, the MO_(Y) oxide powder, and the ZnO_(Z)oxide powder are mixed in a predetermined molar ratio.

For example, the predetermined molar ratio of the InO_(X) oxide powder,the MO_(Y) oxide powder, and the ZnO_(Z) oxide powder is 2:2:1, 8:4:3,3:1:1, 1:1:1, 4:2:3, 1:1:2, 3:1:4, or 3:1:2. With such a molar ratio, asputtering target including a polycrystalline oxide with highcrystallinity can be obtained easily later.

Next, in a step S102, an In-M-Zn oxide is obtained by performing firstbaking on the InO_(X) oxide powder, the MO_(Y) oxide powder, and theZnO_(Z) oxide powder which are mixed in a predetermined molar ratio.

Note that the first baking is performed in an inert atmosphere, anoxidation atmosphere, or under a reduced pressure at a temperaturehigher than or equal to 400° C. and lower than or equal to 1700° C.,preferably higher than or equal to 900° C. and lower than or equal to1500° C. The first baking is performed for longer than or equal to 3minutes and shorter than or equal to 24 hours, preferably longer than orequal to 30 minutes and shorter than or equal to 17 hours, furtherpreferably longer than or equal to 30 minutes and shorter than or equalto 5 hours, for example. When the first baking is performed under theabove conditions, secondary reactions other than the main reaction canbe suppressed, and the impurity concentration in the In-M-Zn oxidepowder can be reduced. Accordingly, the crystallinity of the In-M-Znoxide powder can be increased.

The first baking may be performed plural times at different temperaturesand/or in different atmospheres. For example, the In-M-Zn oxide powdermay be first held at a first temperature in a first atmosphere and thenat a second temperature in a second atmosphere. Specifically, it ispreferable that the first atmosphere be an inert atmosphere or under areduced pressure and the second atmosphere be an oxidation atmosphere.This is because an oxygen vacancy is generated in some cases in theIn-M-Zn oxide when impurities contained in the In-M-Zn oxide powder arereduced in the first atmosphere. Therefore, it is preferable that oxygenvacancies in the obtained In-M-Zn oxide be reduced in the secondatmosphere. The impurity concentration and oxygen vacancies in theIn-M-Zn oxide are reduced, whereby the crystallinity of the In-M-Znoxide powder can be increased.

Next, the In-M-Zn oxide powder is obtained by grinding the In-M-Zn oxidein a step S103.

The In-M-Zn oxide has a high proportion of crystals with surfacestructures of planes parallel to the a-b plane. Therefore, the obtainedIn-M-Zn oxide powder includes many flat plate-like crystal grains whosetop and bottom surfaces are parallel to the a-b plane. Moreover, thecrystal of the In-M-Zn oxide has, in many cases, a hexagonal or trigonal(rhombohedral) crystal structure; therefore, in many cases, the aboveflat plate-like crystal grains each have the shape of a hexagonalcylinder whose top and bottom surfaces are approximately equilateralhexagons each having interior angles of 120°.

Next, the grain size of the obtained In-M-Zn oxide powder is checked ina step S104. Here, the average grain size of the In-M-Zn oxide powder ischecked to be less than or equal to 3 μm, preferably less than or equalto 2.5 μm, further preferably less than or equal to 2 μm. Note that thestep S104 may be omitted and only the In-M-Zn oxide powder whose grainsize is less than or equal to 3 μm, preferably less than or equal to 2.5μm, further preferably less than or equal to 2 μm may be sifted using agrain size filter. The average grain size of the In-M-Zn oxide powdercan be certainly less than or equal to 3 μm, preferably less than orequal to 2.5 μm, further preferably less than or equal to 2 μm bysifting the In-M-Zn oxide powder whose grain size is less than or equalto 3 μm, preferably less than or equal to 2.5 μm, further preferablyless than or equal to 2 μm.

In the case where the average grain size of the In-M-Zn oxide powderexceeds a predetermined size in the step S104, the procedure returns tothe step S103 and the In-M-Zn oxide powder is ground again.

In the above manner, the In-M-Zn oxide powder whose average grain sizeis less than or equal to 3 μm, preferably less than or equal to 2.5 μm,further preferably less than or equal to 2 μm can be obtained. Note thatthe grain size of a crystal grain included in a sputtering target to bemanufactured later can be reduced by obtaining the In-M-Zn oxide powderwhose average grain size is less than or equal to 3 μm, preferably lessthan or equal to 2.5 μm, further preferably less than or equal to 2 μm.

Next, in FIG. 7B, a sputtering target is manufactured using the In-M-Znoxide powder obtained in the flow chart shown in FIG. 7A.

In a step S111, the In-M-Zn oxide powder is made to spread over a moldand molded. Here, molding refers to making powder or the like spreadover a mold to obtain a uniform thickness. Specifically, the In-M-Znoxide powder is introduced into the mold, and then vibration isexternally applied so that the In-M-Zn oxide powder is molded.Alternatively, the In-M-Zn oxide powder is introduced into the mold, andthen molding is performed using a roller or the like so as to obtain auniform thickness. Note that in the step S111, slurry in which theIn-M-Zn oxide powder is mixed with water, a dispersant, and a binder maybe molded. In that case, the slurry is poured into the mold and thenmolded by sucking the mold from the bottom. After that, drying treatmentis performed on a molded body after the mold is sucked. The dryingtreatment is preferably natural drying because the molded body is lesslikely to be cracked. After that, the molded body is subjected to heattreatment at a temperature higher than or equal to 300° C. and lowerthan or equal to 700° C., so that residual moisture or the like whichcannot be taken out by natural drying is removed.

When the In-M-Zn oxide powder including many flat plate-like crystalgrains whose top and bottom surfaces are parallel to the a-b plane ismade to spread over the mold and molded, the crystal grains are arrangedwith the planes which are parallel to the a-b plane thereof facingupward. Therefore, the proportion of the surface structures of planesparallel to the a-b plane can be increased in such a manner that theobtained In-M-Zn oxide powder is made to spread over the mold andmolded. Note that the mold may be formed of a metal or an oxide and theupper shape thereof is rectangular or rounded.

Next, in a step S112, second baking is performed on the In-M-Zn oxidepowder. Then, first pressure treatment is performed on the In-M-Zn oxidepowder which has been subjected to the second baking, whereby plate-likeIn-M-Zn oxide is obtained in a step S113. The second baking is performedunder conditions similar to those of the first baking. The crystallinityof the In-M-Zn oxide can be increased by performing the second baking.

Note that the first pressure treatment may be performed in any manner aslong as the In-M-Zn oxide powder can be pressed. For example, a weightwhich is formed of the same kind of material as the mold can be used.Alternatively, the In-M-Zn oxide powder may be pressed under a highpressure using compressed air. Besides, the first pressure treatment canbe performed using various known techniques. Note that the firstpressure treatment may be performed at the same time as the secondbaking.

Planarization treatment may be performed after the first pressuretreatment. As the planarization treatment, chemical mechanical polishing(CMP) treatment or the like can be employed.

The plate-like In-M-Zn oxide thus obtained becomes a polycrystallineoxide with high crystallinity.

Next, the thickness of the obtained plate-like In-M-Zn oxide is checkedin a step S114. When the thickness of the plate-like In-M-Zn oxide isless than a desired thickness, the procedure returns to the step S111and the In-M-Zn oxide powder is made to spread over the plate-likeIn-M-Zn oxide and molded. When the plate-like In-M-Zn oxide has adesired thickness, the plate-like In-M-Zn oxide is used as a sputteringtarget. The description of the case where the thickness of theplate-like In-M-Zn oxide is less than a desired thickness is givenbelow.

Next, in the step S112, third baking is performed on the plate-likeIn-M-Zn oxide and the In-M-Zn oxide powder over the plate-like In-M-Znoxide. Then, in the step S113, second pressure treatment is performed onthe plate-like In-M-Zn oxide and the In-M-Zn oxide powder over theplate-like In-M-Zn oxide which have been subjected to the third baking,whereby a plate-like In-M-Zn oxide whose thickness is increased by thethickness of the In-M-Zn oxide powder is obtained. A plate-like In-M-Znoxide with an increased thickness is obtained through crystal growthwith the use of the plate-like In-M-Zn oxide as a seed crystal;therefore, the plate-like In-M-Zn oxide is a polycrystalline oxide withhigh crystallinity.

Note that the third baking is performed under conditions similar tothose of the second baking. The second pressure treatment is performedunder conditions similar to those of the first pressure treatment. Notethat the second pressure treatment may be performed at the same time asthe third baking.

The thickness of the obtained plate-like In-M-Zn oxide is checked againin the step S114.

Through the above steps, the thickness of the plate-like In-M-Zn oxidecan be gradually increased while the crystal alignment is improved.

By repeating these steps of increasing the thickness of a plate-likeIn-M-Zn oxide n times (n is a natural number), the plate-like In-M-Znoxide having a desired thickness (t), for example, greater than or equalto 2 mm and less than or equal to 20 mm, preferably greater than orequal to 3 mm and less than or equal to 20 mm can be obtained. Theplate-like In-M-Zn oxide is used as a sputtering target.

After that, planarization treatment may be performed.

Note that fourth baking may be performed on the obtained sputteringtarget. The fourth baking is performed under conditions similar to thoseof the first baking. A sputtering target including a polycrystallineoxide with much higher crystallinity can be obtained by performing thefourth baking.

In the above manner, the sputtering target which includes apolycrystalline In—Zn oxide containing a plurality of crystal grainshaving cleavage planes parallel to the a-b plane and a small averagegrain size can be manufactured.

Note that the sputtering target formed in such a manner can have highdensity. When the density of the sputtering target is increased, thedensity of a film to be formed can also be increased. Specifically, therelative density of the sputtering target can be set to 90% or higher,preferably 95% or higher, further preferably 99% or higher.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 3

In this embodiment, another example of the stacked-layer structure ofthe semiconductor device of one embodiment of the present invention willbe described with reference to FIGS. 8A and 8B. Specifically, in thisembodiment, the case in which the oxide semiconductor layer described inEmbodiment 1 has a stacked-layer structure of a first oxidesemiconductor layer including a nanocrystal, a second oxidesemiconductor layer including a CAAC-OS, and a third oxide semiconductorlayer including a nanocrystal is given as an example.

FIG. 8A is a cross-sectional view of oxide semiconductor layers betweeninsulating layers. FIG. 8B shows a band structure along line X1-Y1 inFIG. 8A.

The stacked-layer structure of this embodiment includes an oxidesemiconductor layer 404 between an insulating layer 402 and aninsulating layer 410, and the oxide semiconductor layer 404 includes afirst oxide semiconductor layer 404 a, a second oxide semiconductorlayer 404 b, and a third oxide semiconductor layer 404 c.

As the second oxide semiconductor layer 404 b included in the oxidesemiconductor layer 404, an oxide semiconductor layer including aCAAC-OS is used. Further, as the second oxide semiconductor layer 404 b,an oxide semiconductor layer having higher electron affinity than thefirst oxide semiconductor layer 404 a and the third oxide semiconductorlayer 404 c is used. For example, as the second oxide semiconductorlayer 404 b, an oxide semiconductor layer having higher electronaffinity than the first oxide semiconductor layer 404 a and the thirdoxide semiconductor layer 404 c by greater than or equal to 0.07 eV andless than or equal to 1.3 eV, preferably greater than or equal to 0.1 eVand less than or equal to 0.7 eV, further preferably greater than orequal to 0.15 eV and less than or equal to 0.4 eV is used.

Note that the electron affinity refers to an energy difference betweenthe vacuum level and the conduction band minimum. In FIG. 8B, theconduction band minimum energy of the first oxide semiconductor layer404 a, that of the second oxide semiconductor layer 404 b, and that ofthe third oxide semiconductor layer 404 c are denoted by Ec1, Ec2, andEc3, respectively. The valence band maximum energy of the first oxidesemiconductor layer 404 a, that of the second oxide semiconductor layer404 b, and that of the third oxide semiconductor layer 404 c are denotedby Ev1, Ev2, and Ev3, respectively.

At least as one of the first oxide semiconductor layer 404 a and thethird oxide semiconductor layer 404 c included in the oxidesemiconductor layer 404, an oxide semiconductor layer including ananocrystal is used. In this embodiment, an oxide semiconductor layerincluding a nanocrystal is used as both of the first oxide semiconductorlayer 404 a and the third oxide semiconductor layer 404 c.

Moreover, for the first oxide semiconductor layer 404 a and the thirdoxide semiconductor layer 404 c, an oxide semiconductor layer whoseenergy gap is larger than an energy gap Eg2 of the second oxidesemiconductor layer 404 b is used. For example, an energy gap Eg1 of thefirst oxide semiconductor layer 404 a and an energy gap Eg3 of the thirdoxide semiconductor layer 404 c are greater than or equal to 2.7 eV andless than or equal to 4.9 eV, preferably greater than or equal to 3 eVand less than or equal to 4.7 eV, further preferably greater than orequal to 3.2 eV and less than or equal to 4.4 eV. Note that the energygap Eg2 of the second oxide semiconductor layer 404 b is smaller thanthe energy gaps Eg1 and Eg3, for example, greater than or equal to 2.5eV and less than or equal to 4.2 eV, preferably greater than or equal to2.8 eV and less than or equal to 3.8 eV, further preferably greater thanor equal to 3 eV and less than or equal to 3.5 eV.

When an electric field is applied to a gate electrode layer in such astructure, the second oxide semiconductor layer 404 b of the oxidesemiconductor layer 404 whose conduction band minimum energy is thelowest serves as a main current path. In other words, the first oxidesemiconductor layer 404 a is formed between the second oxidesemiconductor layer 404 b and the insulating layer 402 and the thirdoxide semiconductor layer 404 c is formed between the second oxidesemiconductor layer 404 b and the insulating layer 410, whereby astructure in which a channel of a transistor is not in contact with agate insulating layer can be obtained.

The second oxide semiconductor layer 404 b has higher film density and alower defect state density than the first oxide semiconductor layer 404a and the third oxide semiconductor layer 404 c. Thus, it is possible tosuppress a change in electrical characteristics of the transistor due todefect states by formation of a channel in the second oxidesemiconductor layer 404 b; accordingly, a highly reliable transistor canbe obtained.

Further, an oxide semiconductor layer with low carrier density is usedas the second oxide semiconductor layer 404 b. For example, an oxidesemiconductor layer whose carrier density is lower than or equal to1×10¹⁷/cm³, preferably lower than or equal to 1×10¹⁵/cm³, furtherpreferably lower than or equal to 1×10¹³/cm³, still further preferablylower than or equal to 1×10¹¹/cm³ is used as the second oxidesemiconductor layer 404 b.

The second oxide semiconductor layer 404 b contains at least indium. Thesecond oxide semiconductor layer 404 b preferably contains at leastindium in order that the carrier mobility (electron mobility) is high.In addition to indium, an element M (aluminum, gallium, yttrium,zirconium, or tin) is preferably contained.

The first oxide semiconductor layer 404 a contains one or more kinds ofelements contained in the second oxide semiconductor layer 404 b.Further, since the first oxide semiconductor layer 404 a contains one ormore kinds of elements contained in the second oxide semiconductor layer404 b, interface scattering is less likely to occur at the interfacebetween the second oxide semiconductor layer 404 b and the first oxidesemiconductor layer 404 a. Thus, the transistor can have a highfield-effect mobility because the movement of carriers is not hinderedat the interface.

The first oxide semiconductor layer 404 a may contain a larger amountof, for example, aluminum, titanium, silicon, gallium, germanium,yttrium, zirconium, tin, lanthanum, cerium, or hafnium in an atomicratio than that of indium in an atomic ratio. Specifically, the amountof any of the above elements in the first oxide semiconductor layer 404a in an atomic ratio is 1.5 times or more, preferably 2 times or more,further preferably 3 times or more as large as that of indium in anatomic ratio. The above elements increase the energy gap of the oxidesemiconductor layer in some cases. When a large amount of any of theabove elements in an atomic ratio is contained in the oxidesemiconductor layer, it decreases the electron affinity of the oxidesemiconductor layer in some cases. Any of the above elements is morestrongly bonded to oxygen than indium is, and thus has a function ofsuppressing generation of an oxygen vacancy in the oxide semiconductorlayer. The above elements block an impurity of the oxide semiconductorlayer or reduce the diffusion coefficient of an impurity in some cases.Further, the first oxide semiconductor layer 404 a contains a largeramount of any of the above elements in an atomic ratio than that in thesecond oxide semiconductor layer 404 b in an atomic ratio.

The third oxide semiconductor layer 404 c contains one or more kinds ofelements contained in the second oxide semiconductor layer 404 b.Further, since the third oxide semiconductor layer 404 c contains one ormore kinds of elements contained in the second oxide semiconductor layer404 b, interface scattering is less likely to occur at the interfacebetween the second oxide semiconductor layer 404 b and the third oxidesemiconductor layer 404 c. Thus, the transistor can have a highfield-effect mobility because the movement of carriers is not hinderedat the interface.

The third oxide semiconductor layer 404 c may contain a larger amountof, for example, aluminum, titanium, silicon, gallium, germanium,yttrium, zirconium, tin, lanthanum, cerium, or hafnium in an atomicratio than that of indium in an atomic ratio. Specifically, the amountof any of the above elements in the third oxide semiconductor layer 404c in an atomic ratio is 1.5 times or more, preferably 2 times or more,further preferably 3 times or more as large as that of indium in anatomic ratio. Note that the third oxide semiconductor layer 404 ccontains any of the above elements in a higher atomic ratio than thesecond oxide semiconductor layer 404 b.

Note that the first oxide semiconductor layer 404 a and the third oxidesemiconductor layer 404 c may have different physical properties or thesame physical properties.

In the case of using an In-M-Zn oxide for the first oxide semiconductorlayer 404 a, when Zn and oxygen are eliminated from consideration, theproportion of In and the proportion of M are preferably less than 50atomic % and greater than or equal to 50 atomic %, respectively, furtherpreferably less than 25 atomic % and greater than or equal to 75 atomic%, respectively. In the case of using an In-M-Zn oxide for the secondoxide semiconductor layer 404 b, when Zn and oxygen are eliminated fromconsideration, the proportion of In and the proportion of M arepreferably greater than or equal to 25 atomic % and less than 75 atomic%, respectively, further preferably greater than or equal to 34 atomic %and less than 66 atomic %, respectively. In the case of using an In-M-Znoxide for the third oxide semiconductor layer 404 c, when Zn and oxygenare eliminated from consideration, the proportion of In and theproportion of M are preferably less than 50 atomic % and greater than orequal to 50 atomic %, respectively, further preferably less than 25atomic % and greater than or equal to 75 atomic %, respectively.

The thickness of the first oxide semiconductor layer 404 a is greaterthan or equal to 5 nm and less than or equal to 100 nm, preferablygreater than or equal to 5 nm and less than or equal to 50 nm. Thethickness of the second oxide semiconductor layer 404 b is greater thanor equal to 5 nm and less than or equal to 200 nm, preferably greaterthan or equal to 5 nm and less than or equal to 100 nm, furtherpreferably greater than or equal to 5 nm and less than or equal to 50nm. The thickness of the third oxide semiconductor layer 404 c isgreater than or equal to 5 nm and less than or equal to 100 nm,preferably greater than or equal to 5 nm and less than or equal to 50nm.

Since each of the first oxide semiconductor layer 404 a and the thirdoxide semiconductor layer 404 c contains one or more kinds of metalelements contained in the second oxide semiconductor layer 404 b, theoxide semiconductor layer 404 can also be referred to as an oxide stackin which layers containing the same main components are stacked. Theoxide stack in which layers containing the same main components arestacked is formed to have not only a simple stacked-layer structure ofthe layers but also a continuous energy band (here, in particular, awell structure having a U shape in which the conduction band minimumenergies are changed continuously between the layers). This is becausewhen an impurity which forms a defect state such as a trapping center ora recombination center is mixed at an interface between the layers, thecontinuity of the energy band is lost, and thus carriers are trapped ordisappear by recombination at the interface.

In order to form continuous junction, the layers need to be stackedsuccessively without being exposed to the air by using a multi-chamberdeposition system (sputtering apparatus) provided with a load lockchamber. It is preferable that each chamber of the sputtering apparatusbe able to be evacuated to a high vacuum (to about 5×10⁻⁷ Pa to 1×10⁻⁴Pa) by an adsorption vacuum pump such as a cryopump so that water andthe like acting as impurities of the oxide semiconductor are removed asmuch as possible. Alternatively, a combination of a turbo molecular pumpand a cold trap is preferably used to prevent back-flow of a gas from anexhaust system into the chamber.

Not only high vacuum evacuation of the chamber but also highpurification of a sputtering gas is necessary to reduce hydrogen andoxygen vacancies that cause defect states in the oxide semiconductorlayer and obtain a highly purified intrinsic oxide semiconductor layer.As an oxygen gas or an argon gas used as the sputtering gas, a gas thatis highly purified to have a dew point of −40° C. or lower, preferably−80° C. or lower, further preferably −100° C. or lower is used, so thatentry of moisture or the like into the oxide semiconductor can beprevented as much as possible.

Each of the first oxide semiconductor layer 404 a and the third oxidesemiconductor layer 404 c which are provided over and under the secondoxide semiconductor layer 404 b can serve as a barrier layer, andsuppress the adverse effect of a defect state which is formed at theinterface between the oxide semiconductor layer 404 and each of theinsulating layers in contact with the oxide semiconductor layer 404 onthe second oxide semiconductor layer 404 b which serves as a maincarrier path for the transistor.

For example, oxygen vacancies in the oxide semiconductor layer appear aslocalized states in deep energy area in the energy gap of the oxidesemiconductor. A carrier is trapped in such localized states, so thatthe reliability of the transistor is reduced. For this reason, oxygenvacancies in the oxide semiconductor layer need to be reduced. The oxidesemiconductor layers whose compositions are less likely to cause anoxygen vacancy than the composition of the second oxide semiconductorlayer 404 b are provided over and under and in contact with the secondoxide semiconductor layer 404 b in the oxide semiconductor layer 404,whereby oxygen vacancies in the second oxide semiconductor layer 404 bcan be reduced.

In addition, when the second oxide semiconductor layer 404 b is incontact with an insulating layer including a different constituentelement (e.g., a base insulating layer including a silicon oxide film),an interface state is sometimes formed at the interface of the twolayers and the interface state forms a channel. At this time, in somecases, a second transistor having a different threshold voltage isformed and accordingly an apparent threshold voltage of the transistoris fluctuated. However, since the first oxide semiconductor layer 404 acontains one or more kinds of metal elements contained in the secondoxide semiconductor layer 404 b in the oxide semiconductor layer 404, aninterface state is less likely to be formed at the interface between thefirst oxide semiconductor layer 404 a and the second oxide semiconductorlayer 404 b. Thus, with the first oxide semiconductor layer 404 a,variations in electrical characteristics of the transistors, such as athreshold voltage, can be reduced.

In the case where a channel is formed at the interface between a gateinsulating layer (here, assumed to be the insulating layer 410) and thesecond oxide semiconductor layer 404 b, interface scattering occurs atthe interface and the field-effect mobility of the transistor isdecreased. However, since the third oxide semiconductor layer 404 ccontains one or more kinds of metal elements contained in the secondoxide semiconductor layer 404 b in the oxide semiconductor layer 404,scattering of carriers is less likely to occur at the interface betweenthe second oxide semiconductor layer 404 b and the third oxidesemiconductor layer 404 c, and thus the field-effect mobility of thetransistor can be increased.

Further, each of the first oxide semiconductor layer 404 a and the thirdoxide semiconductor layer 404 c also serves as a barrier layer whichsuppresses formation of impurity levels due to the entry of theconstituent elements of the insulating layers which are in contact withthe oxide semiconductor layer 404 into the second oxide semiconductorlayer 404 b.

For example, in the case of using a silicon-containing insulating layeras each of the insulating layers 402 and 410 which are in contact withthe oxide semiconductor layer 404, the silicon in the insulating layersor carbon which might be contained in the insulating layers in somecases enters the first oxide semiconductor layer 404 a or the thirdoxide semiconductor layer 404 c at a depth of several nanometers fromthe interface. An impurity such as silicon or carbon entering the oxidesemiconductor layer forms impurity levels. The impurity levels serve asa donor and generates an electron, so that an n-type region is sometimesformed in the oxide semiconductor layer.

However, when the thicknesses of the first oxide semiconductor layer 404a and the third oxide semiconductor layer 404 c are larger than severalnanometers, the impurity such as silicon or carbon which has entered theoxide semiconductor layer does not reach the second oxide semiconductorlayer 404 b, so that the influence of impurity levels is suppressed.

Here, the concentration of silicon contained in the oxide semiconductorlayer is lower than or equal to 3×10¹⁸/cm³, preferably lower than orequal to 3×10¹⁷/cm³. In addition, the concentration of carbon containedin the oxide semiconductor layer is lower than or equal to 3×10¹⁸/cm³,preferably lower than or equal to 3×10¹⁷/cm³. It is particularlypreferable to sandwich or surround the second oxide semiconductor layer404 b which serves as a carrier path by the first oxide semiconductorlayer 404 a and the third oxide semiconductor layer 404 c in order toprevent entry of much silicon or carbon which is a Group 14 element intothe second oxide semiconductor layer 404 b. That is, the concentrationsof silicon and carbon contained in the second oxide semiconductor layer404 b are preferably lower than those in the first oxide semiconductorlayer 404 a and the third oxide semiconductor layer 404 c.

Note that the impurity concentration in the oxide semiconductor layercan be measured by secondary ion mass spectrometry (SIMS).

If hydrogen or moisture is contained in the oxide semiconductor layer asan impurity, it can work as a donor and form an n-type region;therefore, in order to achieve a well-shaped structure, it is useful toprovide a protective insulating layer (e.g., a silicon nitride layer)for preventing entry of hydrogen or moisture from the outside into theupper portion of the oxide semiconductor layer 404.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 4

In this embodiment, a structure example of a transistor including theoxide semiconductor layer described in Embodiment 1 or 3 will bedescribed with reference to drawings.

<Structure Example of Transistor>

FIG. 9A is a schematic cross-sectional view of a transistor 300. Thetransistor 300 exemplified by this structure example is a bottom-gatetransistor.

The transistor 300 includes a gate electrode layer 302 provided over asubstrate 301, an insulating layer 303 provided over the substrate 301and the gate electrode layer 302, an oxide semiconductor layer 314provided over the insulating layer 303 to overlap with the gateelectrode layer 302, and a source electrode layer 305 a and a drainelectrode layer 305 b which are in contact with the top surface of theoxide semiconductor layer 314. Moreover, an insulating layer 306 coversthe insulating layer 303, the oxide semiconductor layer 314, and thesource electrode layer 305 a and the drain electrode layer 305 b; and aninsulating layer 307 is provided over the insulating layer 306.

The oxide semiconductor layer 314 included in the transistor 300 has astacked-layer structure of an oxide semiconductor layer 314 a and anoxide semiconductor layer 314 b. Note that a boundary between the oxidesemiconductor layer 314 a and the oxide semiconductor layer 314 b isshown by broken lines in FIG. 9A and the like because the boundary isnot clear in some cases.

Both the oxide semiconductor layer 314 a and the oxide semiconductorlayer 314 b are crystalline oxide semiconductor layers, which havedifferent crystallinity. In this embodiment, for the oxide semiconductorlayer 314 a, an oxide semiconductor layer having higher film quality anda lower defect state density than the oxide semiconductor layer 314 b isused. Preferably, the oxide semiconductor layer 314 a is a CAAC-OS film,and the oxide semiconductor layer 314 b is a nanocrystalline oxidesemiconductor layer. In other words, the oxide semiconductor layer 314of the transistor 300 in this embodiment corresponds to the oxidesemiconductor layer 114 described in Embodiment 1 with reference to FIG.1B. The insulating layer 306 of the transistor 300 corresponds to theinsulating layer 106 described in Embodiment 1 with reference to FIG.1B.

Typical examples of a material of the oxide semiconductor layer 314 aare In—Ga oxide, In—Zn oxide, and In-M-Zn oxide (M represents Al, Ti,Ga, Y, Zr, La, Ce, Nd, or Hf). In the case of using an In-M-Zn oxide forthe oxide semiconductor layer 314 a, when Zn and oxygen are eliminatedfrom consideration, the proportion of In and the proportion of M arepreferably greater than or equal to 25 atomic % and less than 75 atomic%, respectively, further preferably greater than or equal to 34 atomic %and less than 66 atomic %, respectively. In addition, the oxidesemiconductor layer 314 a is formed using a material having an energygap of 2 eV or higher, preferably 2.5 eV or higher, further preferably 3eV or higher, for example.

In this embodiment, the oxide semiconductor layer 314 b is formed usingan oxide semiconductor layer which contains one or more kinds of metalelements contained in the oxide semiconductor layer 314 a. For example,an oxide semiconductor layer that is represented by an In-M-Zn oxide (Mis a metal such as Al, Ti, Ga, Ge, Y, Zr, Sn, La, Ce, or Hf) andcontains a larger amount of M in an atomic ratio than that in the oxidesemiconductor layer 314 a in an atomic ratio is used. Specifically, theamount of the element M in the oxide semiconductor layer 314 b in anatomic ratio is 1.5 times or more, preferably 2 times or more, furtherpreferably 3 times or more as large as that of the oxide semiconductorlayer 314 a in an atomic ratio. The element M is more strongly bonded tooxygen than indium is, and thus the oxide semiconductor layer 314 b hasa function of suppressing generation of an oxygen vacancy. Thus, anoxygen vacancy can be less likely to be caused in the oxidesemiconductor layer 314 b than in the oxide semiconductor layer 314 a.

It is preferable to use, as the oxide semiconductor layer 314 b, anoxide semiconductor which is an In-M-Zn oxide (M represents Al, Ti, Ga,Y, Zr, La, Ce, Nd, or Hf) and whose conduction band minimum is closer toa vacuum level than that of the oxide semiconductor used as the oxidesemiconductor layer 314 a. For example, the difference in the conductionband minimum energy between the oxide semiconductor layer 314 b and theoxide semiconductor layer 314 a is preferably 0.05 eV or more, 0.07 eVor more, 0.1 eV or more, or 0.15 eV or more and 2 eV or less, 1 eV orless, 0.5 eV or less, or 0.4 eV or less.

For example, in the case of using an In-M-Zn oxide for the oxidesemiconductor layer 314 b, when Zn and oxygen are eliminated fromconsideration, the proportion of In and the proportion of M arepreferably less than 50 atomic % and greater than or equal to 50 atomic%, respectively, further preferably less than 25 atomic % and greaterthan or equal to 75 atomic %, respectively.

For example, as the oxide semiconductor layer 314 a, an In—Ga—Zn oxidein which an atomic ratio of In to Ga and Zn is 1:1:1 or 3:1:2 can beused. As the oxide semiconductor layer 314 b, an In—Ga—Zn oxide in whichan atomic ratio of In to Ga and Zn is 1:3:2, 1:6:4, or 1:9:6 can beused. Note that the atomic ratio of each of the oxide semiconductorlayers 314 a and 314 b may vary within a margin of ±20% of thecorresponding atomic ratio.

However, the compositions are not limited to those described above, anda material having the appropriate composition may be used depending onrequired semiconductor characteristics and electrical characteristics ofthe transistor (e.g., field-effect mobility and threshold voltage).Further, in order to obtain the required semiconductor characteristicsof the transistor, it is preferable that the carrier density, theimpurity concentration, the defect density, the atomic ratio of a metalelement to oxygen, the interatomic distance, the density, and the likeof the oxide semiconductor layers 314 a and 314 b be set to appropriatevalues.

Although the oxide semiconductor layer 314 is a stack of two oxidesemiconductor layers in the above structure, it may be a stack of threeor more oxide semiconductor layers.

<<Substrate 301>>

There is no particular limitation on the property of a material and thelike of the substrate 301 as long as the material has heat resistanceenough to withstand at least heat treatment which will be performedlater. For example, a glass substrate, a ceramic substrate, a quartzsubstrate, a sapphire substrate, or a yttria-stabilized zirconia (YSZ)substrate may be used as the substrate 301. Alternatively, a singlecrystal semiconductor substrate or a polycrystalline semiconductorsubstrate made of silicon, silicon carbide, or the like, a compoundsemiconductor substrate made of silicon germanium or the like, an SOIsubstrate, or the like can be used as the substrate 301. Stillalternatively, any of these substrates provided with a semiconductorelement may be used as the substrate 301.

Still alternatively, a flexible substrate such as a plastic substratemay be used as the substrate 301, and the transistor 300 may be provideddirectly on the flexible substrate. Further alternatively, a separationlayer may be provided between the substrate 301 and the transistor 300.The separation layer can be used when part or the whole of thetransistor formed over the separation layer is formed and separated fromthe substrate 301 and transferred to another substrate. Thus, thetransistor 300 can be transferred to a substrate having low heatresistance or a flexible substrate.

<<Gate Electrode Layer 302>>

The gate electrode layer 302 can be formed using a metal selected fromaluminum, chromium, copper, tantalum, titanium, molybdenum, andtungsten; an alloy containing any of these metals as a component; analloy containing any of these metals in combination; or the like.Further, one or more metals selected from manganese and zirconium may beused. Furthermore, the gate electrode layer 302 may have a single-layerstructure or a stacked-layer structure of two or more layers. Forexample, a single-layer structure of an aluminum film containingsilicon, a two-layer structure in which a titanium film is stacked overan aluminum film, a two-layer structure in which a titanium film isstacked over a titanium nitride film, a two-layer structure in which atungsten film is stacked over a titanium nitride film, a two-layerstructure in which a tungsten film is stacked over a tantalum nitridefilm or a tungsten nitride film, a three-layer structure in which atitanium film, an aluminum film, and a titanium film are stacked in thisorder, and the like can be given. Alternatively, an alloy filmcontaining aluminum and one or more metals selected from titanium,tantalum, tungsten, molybdenum, chromium, neodymium, and scandium; or anitride film of the alloy film may be used.

The gate electrode layer 302 can also be formed using alight-transmitting conductive material such as indium tin oxide, indiumoxide containing tungsten oxide, indium zinc oxide containing tungstenoxide, indium oxide containing titanium oxide, indium tin oxidecontaining titanium oxide, indium zinc oxide, or indium tin oxide towhich silicon oxide is added. It is also possible to have astacked-layer structure formed using the above light-transmittingconductive material and the above metal.

Further, an In—Ga—Zn-based oxynitride semiconductor film, an In—Sn-basedoxynitride semiconductor film, an In—Ga-based oxynitride semiconductorfilm, an In—Zn-based oxynitride semiconductor film, a Sn-basedoxynitride semiconductor film, an In-based oxynitride semiconductorfilm, a film of metal nitride (such as InN or ZnN), or the like may beprovided between the gate electrode layer 302 and the insulating layer303. These films each have a work function higher than or equal to 5 eV,preferably higher than or equal to 5.5 eV, which is higher than theelectron affinity of an oxide semiconductor; thus, the threshold voltageof a transistor including an oxide semiconductor can shift in thepositive direction. Accordingly, a switching element having what iscalled normally-off characteristics can be achieved. For example, in thecase of using an In—Ga—Zn-based oxynitride semiconductor film, anIn—Ga—Zn-based oxynitride semiconductor film having a higher nitrogenconcentration than at least the oxide semiconductor layer 314,specifically, an In—Ga—Zn-based oxynitride semiconductor film having anitrogen concentration of 7 atomic % or higher is used.

<<Insulating Layer 303>>

The insulating layer 303 functions as a gate insulating film. Theinsulating layer 303 in contact with the bottom surface of the oxidesemiconductor layer 314 is preferably an amorphous film.

The insulating layer 303 may be formed to have a single-layer structureor a stacked-layer structure using, for example, one or more of asilicon oxide film, a silicon oxynitride film, a silicon nitride oxidefilm, a silicon nitride film, an aluminum oxide film, a hafnium oxidefilm, a gallium oxide film, and a Ga—Zn-based metal oxide film.

Further, the insulating layer 303 may be formed using a high-k materialsuch as hafnium silicate (HfSiO_(x)), hafnium silicate to which nitrogenis added (HfSi_(x)O_(y)N_(z)), hafnium aluminate to which nitrogen isadded (HfAl_(x)O_(y)N_(z)), hafnium oxide, or yttrium oxide, so thatgate leakage current of the transistor can be reduced.

<<Source Electrode Layer 305 a and Drain Electrode Layer 305 b>>

The source electrode layer 305 a and the drain electrode layer 305 b canbe formed to have a single-layer structure or a stacked-layer structureusing, as a conductive material, any of single metals such as aluminum,titanium, chromium, nickel, copper, yttrium, zirconium, molybdenum,silver, tantalum, and tungsten, or an alloy containing any of thesesingle metals as its main component. For example, a single-layerstructure of an aluminum film containing silicon, a two-layer structurein which a titanium film is stacked over an aluminum film, a two-layerstructure in which a titanium film is stacked over a tungsten film, atwo-layer structure in which a copper film is formed over acopper-magnesium-aluminum alloy film, a three-layer structure in which atitanium film or a titanium nitride film, an aluminum film or a copperfilm, and a titanium film or a titanium nitride film are stacked in thisorder, a three-layer structure in which a molybdenum film or amolybdenum nitride film, an aluminum film or a copper film, and amolybdenum film or a molybdenum nitride film are stacked in this order,and the like can be given. Note that a transparent conductive materialcontaining indium oxide, tin oxide, or zinc oxide may be used.

A material which is capable of removing oxygen from part of the oxidesemiconductor layer 314 to generate an oxygen vacancy is preferably usedfor regions of the source electrode layer 305 a and the drain electrodelayer 305 b which are in contact with at least the oxide semiconductorlayer 314. The carrier concentrations of the regions of the oxidesemiconductor layer 314 in which oxygen vacancies are generated areincreased, so that the regions become n-type regions (n⁺ layers).Accordingly, the regions can function as a source region and a drainregion. Examples of the material which is capable of removing oxygenfrom the oxide semiconductor layer 314 to generate an oxygen vacancyinclude tungsten and titanium.

Further, the entire region overlapping with the source electrode layer305 a of the oxide semiconductor layer 314 and the entire regionoverlapping with the drain electrode layer 305 b of the oxidesemiconductor layer 314 may serve as the source region and the drainregion, respectively, depending on a material for forming the oxidesemiconductor layer 314 or the thickness thereof.

When the source region and the drain region are formed in the oxidesemiconductor layer 314, contact resistance between the oxidesemiconductor layer 314 and each of the source electrode layer 305 a andthe drain electrode layer 305 b can be reduced. Accordingly, theelectrical characteristics of the transistor, such as the field-effectmobility and the threshold voltage, can be made favorable.

<<Insulating Layers 306 and 307>>

The insulating layer 306 is preferably formed using an oxide insulatingfilm that contains oxygen at a higher proportion than oxygen in thestoichiometric composition. Part of oxygen is released by heating fromthe oxide insulating film that contains oxygen at a higher proportionthan oxygen in the stoichiometric composition. The oxide insulating filmthat contains oxygen at a higher proportion than oxygen in thestoichiometric composition is an oxide insulating film in which theamount of released oxygen converted into oxygen atoms is greater than orequal to 1.0×10¹⁸ atoms/cm³, preferably greater than or equal to3.0×10²⁰ atoms/cm³ in thermal desorption spectroscopy (TDS) analysis.

As the insulating layer 306, an insulating layer such as a silicon oxidelayer or a silicon oxynitride layer can be used.

Note that the insulating layer 306 also functions as a film whichrelieves damage to the oxide semiconductor layer 314 at the time offorming the insulating layer 307 later.

Moreover, an oxide film through which oxygen is permeated may beprovided between the insulating layer 306 and the oxide semiconductorlayer 314.

As the oxide film through which oxygen is permeated, an insulating layersuch as a silicon oxide layer or a silicon oxynitride layer can be used.Note that in this specification, a “silicon oxynitride film” refers to afilm that includes more oxygen than nitrogen, and a “silicon nitrideoxide film” refers to a film that includes more nitrogen than oxygen.

The insulating layer 307 can be formed using an insulating film having ablocking effect against oxygen, hydrogen, water, and the like. Providingthe insulating layer 307 over the insulating layer 306 can preventoutward diffusion of oxygen from the oxide semiconductor layer 314 andentry of hydrogen, water, or the like into the oxide semiconductor layer314 from the outside. Examples of the insulating film having a blockingeffect against oxygen, hydrogen, water, and the like are insulatinglayers such as a silicon nitride layer, a silicon nitride oxide layer,an aluminum oxide layer, an aluminum oxynitride layer, a gallium oxidelayer, a gallium oxynitride layer, an yttrium oxide layer, an yttriumoxynitride layer, a hafnium oxide layer, and a hafnium oxynitride layer.

Note that it is also possible to provide a channel protective film overa channel formation region of the oxide semiconductor layer 314. Channelprotective films can also be provided between the source electrode layer305 a and the oxide semiconductor layer 314 and between the drainelectrode layer 305 b and the oxide semiconductor layer 314. A channelprotective transistor is obtained in the case where such channelprotective films are provided. As an example, a silicon oxide film or asilicon oxynitride film can be used as a channel protective film. In thecase of forming a silicon oxide film or a silicon oxynitride film, adeposition gas containing silicon and an oxidizing gas are preferablyused as a source gas. Typical examples of the deposition gas containingsilicon include silane, disilane, trisilane, and silane fluoride. As theoxidizing gas, oxygen, ozone, dinitrogen monoxide, and nitrogen dioxidecan be given as examples.

<Modification Example of Transistor 300>

Examples of the structure of a transistor that is partly different fromthe transistor 300 is described below.

Modification Example 1

FIG. 9B is a schematic cross-sectional view of a transistor 310. Thetransistor 310 differs from the transistor 300 in the structure of theoxide semiconductor layer.

In the transistor 310, an oxide semiconductor layer 304 includes anoxide semiconductor layer 304 a and an oxide semiconductor layer 304 b.An oxide semiconductor layer including a nanocrystal is used as theoxide semiconductor layer 304 a. An oxide semiconductor layer havinghigher film quality and a lower defect state density than the oxidesemiconductor layer 304 a is used as the oxide semiconductor layer 304b. Preferably, a CAAC-OS film is used for the oxide semiconductor layer304 b. In other words, the oxide semiconductor layer 304 of thetransistor 310 in this embodiment corresponds to the oxide semiconductorlayer 104 described in Embodiment 1 with reference to FIG. 1A. Theinsulating layer 303 of the transistor 310 corresponds to the insulatinglayer 102 described in Embodiment 1 with reference to FIG. 1A.

Note that the transistor 310 has the same structure as the transistor300 except the structure of the oxide semiconductor layer 304; thus thedescription of the transistor 300 can be referred to.

Modification Example 2

FIG. 9C is a schematic cross-sectional view of a transistor 320. Thetransistor 320 differs from the transistor 300 and the transistor 310 inthe structure of the oxide semiconductor layer.

In an oxide semiconductor layer 324 included in the transistor 320, anoxide semiconductor layer 324 a, an oxide semiconductor layer 324 b, andan oxide semiconductor layer 324 c are stacked in this order.

The oxide semiconductor layer 324 a and the oxide semiconductor layer324 b are stacked over the insulating layer 303. The oxide semiconductorlayer 324 c is provided in contact with a top surface of the oxidesemiconductor layer 324 b and top and side surfaces of the sourceelectrode layer 305 a and the drain electrode layer 305 b.

An oxide semiconductor layer including a nanocrystal can be used as eachof the oxide semiconductor layer 324 a and the oxide semiconductor layer324 c. An oxide semiconductor layer having higher film quality and alower defect state density than the oxide semiconductor layer 324 a andthe oxide semiconductor layer 324 c is used as the oxide semiconductorlayer 324 b. Preferably, a CAAC-OS film is used for the oxidesemiconductor layer 324 b.

<Example of Method for Manufacturing Transistor>

Next, an example of a method for manufacturing the transistor 300illustrated in FIG. 9A is described.

First, as illustrated in FIG. 10A, the gate electrode layer 302 isformed over the substrate 301, and the insulating layer 303 is formedover the gate electrode layer 302.

Here, a glass substrate is used as the substrate 301.

<<Formation of Gate Electrode Layer>>

A formation method of the gate electrode layer 302 is described below.First, a conductive film is formed by a sputtering method, a CVD method,an evaporation method, or the like and then a resist mask is formed overthe conductive film using a first photomask by a photolithographyprocess. Then, part of the conductive film is etched using the resistmask to form the gate electrode layer 302. After that, the resist maskis removed.

Note that instead of the above formation method, the gate electrodelayer 302 may be formed by an electrolytic plating method, a printingmethod, an ink-jet method, or the like.

<<Formation of Gate Insulating Layer>>

The insulating layer 303 that functions as a gate insulating layer isformed by a sputtering method, a CVD method, an evaporation method, orthe like.

In the case where the insulating layer 303 is formed using a siliconoxide film, a silicon oxynitride film, or a silicon nitride oxide film,a deposition gas containing silicon and an oxidizing gas are preferablyused as a source gas. Typical examples of the deposition gas containingsilicon include silane, disilane, trisilane, and silane fluoride. As theoxidizing gas, oxygen, ozone, dinitrogen monoxide, and nitrogen dioxidecan be given as examples.

In the case of forming a silicon nitride film as the insulating layer303, it is preferable to use a two-step formation method. First, a firstsilicon nitride film with few defects is formed by a plasma CVD methodin which a mixed gas of silane, nitrogen, and ammonia is used as asource gas. Then, a second silicon nitride film in which the hydrogenconcentration is low and hydrogen can be blocked is formed by switchingthe source gas to a mixed gas of silane and nitrogen. With such aformation method, a silicon nitride film having few defects and ablocking property against hydrogen can be formed as the insulating layer303.

Moreover, in the case of forming a gallium oxide film as the insulatinglayer 303, a metal organic chemical vapor deposition (MOCVD) method canbe employed.

<<Formation of Oxide Semiconductor Layer>>

Next, as illustrated in FIG. 10B, the oxide semiconductor layer 304 isformed over the insulating layer 303.

The oxide semiconductor layer 314 can be formed in the manner describedin Embodiment 2. In this embodiment, first, the oxide semiconductorlayer 314 a including a CAAC-OS is formed in the state where thesubstrate 301 is heated and then the oxide semiconductor layer 314 b isformed in the state where the substrate temperature is room temperature.Then, a resist mask is formed over the oxide semiconductor layer 314 busing a photomask by a photolithography process. Subsequently, theisland-like oxide semiconductor layer 314 is formed using the resistmask. After that, the resist mask is removed.

When the oxide semiconductor layer 314 a is formed, the temperature atwhich the substrate 301 is heated is preferably higher than or equal to150° C. and lower than or equal to 450° C., further preferably higherthan or equal to 200° C. and lower than or equal to 350° C. Note that toreduce the impurity concentration in the oxide semiconductor layer, itis effective to form the oxide semiconductor layer in the state wherethe substrate 301 is kept at high temperature.

Note that after the formation of the oxide semiconductor layer 314, heattreatment is preferably performed thereon in order to remove excesshydrogen (including water and a hydroxyl group) contained in the film(to perform dehydration or dehydrogenation). The temperature of the heattreatment is higher than or equal to 300° C. and lower than or equal to700° C., or lower than the strain point of the substrate. The heattreatment can be performed under reduced pressure, a nitrogenatmosphere, or the like. Hydrogen which is an impurity imparting n-typeconductivity can be removed by the heat treatment.

Note that such heat treatment for dehydration or dehydrogenation may beperformed at any timing in the process of manufacturing the transistoras long as the heat treatment is performed after the formation of theoxide semiconductor layer. The heat treatment for dehydration ordehydrogenation may be performed a plurality of times, and may alsoserve as another heat treatment.

In the heat treatment, it is preferable that water, hydrogen, or thelike be not contained in nitrogen or a rare gas such as helium, neon, orargon. The purity of nitrogen or the rare gas such as helium, neon, orargon which is introduced into the heat treatment apparatus is set topreferably 6N (99.9999%) or higher, further preferably 7N (99.99999%) orhigher (i.e., the impurity concentration is preferably 1 ppm or lower,further preferably 0.1 ppm or lower).

In addition, after the oxide semiconductor layer 314 is heated by theheat treatment, a high-purity oxygen gas, a high-purity dinitrogenmonoxide gas, or ultra dry air (the moisture amount is less than orequal to 20 ppm (−55° C. by conversion into a dew point), preferablyless than or equal to 1 ppm, further preferably less than or equal to 10ppb, in the measurement with the use of a dew point meter of a cavityring down laser spectroscopy (CRDS) system) may be introduced into thesame furnace while the heating temperature is maintained or slow coolingis performed to lower the temperature from the heating temperature. Itis preferable that water, hydrogen, or the like be not contained in theoxygen gas or the dinitrogen monoxide gas. The purity of the oxygen gasor the dinitrogen monoxide gas which is introduced into the heattreatment apparatus is preferably 6N or more, further preferably 7N ormore (i.e., the impurity concentration in the oxygen gas or thedinitrogen monoxide gas is preferably 1 ppm or lower, further preferably0.1 ppm or lower). The oxygen gas or the dinitrogen monoxide gas acts tosupply oxygen that is a main component of the oxide semiconductor andthat has been reduced by the step of removing an impurity for thedehydration or dehydrogenation, so that the oxide semiconductor layercan have high purity and be an i-type (intrinsic) oxide semiconductorlayer.

Note that not only high vacuum evacuation of the chamber but also highpurification of a sputtering gas is necessary to obtain a highlypurified intrinsic oxide semiconductor. As an oxygen gas or an argon gasused as the sputtering gas, a gas that is highly purified to have a dewpoint of −40° C. or lower, preferably −80° C. or lower, furtherpreferably −100° C. or lower is used, so that entry of moisture or thelike into the oxide semiconductor can be prevented as much as possible.

Since there is a possibility that oxygen which is a main component of anoxide semiconductor is also released and reduced by dehydration ordehydrogenation treatment, oxygen (including at least one of an oxygenradical, an oxygen atom, and an oxygen ion) may be introduced into theoxide semiconductor layer which has been subjected to the dehydration ordehydrogenation treatment to supply oxygen to the layer.

Introduction (supply) of oxygen into the dehydrated or dehydrogenatedoxide semiconductor layer enables the oxide semiconductor layer to behighly purified and to be i-type (intrinsic). A change in electricalcharacteristics of a transistor including the highly-purified and i-type(intrinsic) oxide semiconductor is suppressed, and the transistor iselectrically stable.

<<Formation of Source Electrode Layer and Drain Electrode Layer>>

Next, as illustrated in FIG. 10C, the source electrode layer 305 a andthe drain electrode layer 305 b are formed.

A formation method of the source electrode layer 305 a and the drainelectrode layer 305 b is described below. First, a conductive film isformed by a sputtering method, a CVD method, an evaporation method, orthe like. Then, a resist mask is formed over the conductive film using athird photomask by a photolithography process. Then, part of theconductive film is etched using the resist mask to form the sourceelectrode layer 305 a and the drain electrode layer 305 b. After that,the resist mask is removed.

Note that as illustrated in FIG. 10C, the upper part of the oxidesemiconductor layer 304 is partly etched and thinned by the etching ofthe conductive film in some cases.

<<Formation of Insulating Layer>>

Next, as illustrated in FIG. 10D, the insulating layer 306 is formedover the oxide semiconductor layer 304, the source electrode layer 305a, and the drain electrode layer 305 b, and the insulating layer 307 issuccessively formed over the insulating layer 306.

In the case of forming a silicon oxide film or a silicon oxynitride filmas the insulating layer 306, a deposition gas containing silicon and anoxidizing gas are preferably used as a source gas. Typical examples ofthe deposition gas containing silicon include silane, disilane,trisilane, and silane fluoride. As the oxidizing gas, oxygen, ozone,dinitrogen monoxide, and nitrogen dioxide can be given as examples.

For example, a silicon oxide film or a silicon oxynitride film can beformed under the following conditions: the substrate placed in atreatment chamber of a plasma CVD apparatus which is vacuum-evacuated isheld at a temperature higher than or equal to 180° C. and lower than orequal to 260° C., preferably higher than or equal to 200° C. and lowerthan or equal to 240° C., the pressure is greater than or equal to 100Pa and less than or equal to 250 Pa, preferably greater than or equal to100 Pa and less than or equal to 200 Pa with introduction of sourcegases into the treatment chamber, and a high-frequency power higher thanor equal to 0.17 W/cm² and lower than or equal to 0.5 W/cm², preferablyhigher than or equal to 0.25 W/cm² and lower than or equal to 0.35 W/cm²is supplied to an electrode provided in the treatment chamber.

As the film formation conditions, the high-frequency power having theabove power density is supplied to the treatment chamber having theabove pressure, whereby the degradation efficiency of the source gas inplasma is increased, oxygen radicals are increased, and oxidation of thesource gas is promoted; therefore, the oxygen content of the oxideinsulating film gets higher than that of the stoichiometric composition.However, the bonding strength of silicon and oxygen is weak in the abovesubstrate temperature range; therefore, part of oxygen is released byheating. Thus, the oxide insulating film can be formed to be an oxideinsulating film that contains oxygen at a higher proportion than oxygenin the stoichiometric composition and from which part of oxygen isreleased by heating.

In the case where an oxide insulating film is provided between the oxidesemiconductor layer 304 and the insulating layer 306, the oxideinsulating film functions as a protective film of the oxidesemiconductor layer 304 in the steps of forming the insulating layer306. Thus, the insulating layer 306 can be formed using thehigh-frequency power with high power density while damage to the oxidesemiconductor layer 304 is reduced.

For example, as the oxide insulating film, a silicon oxide film or asilicon oxynitride film can be formed under the following conditions:the substrate placed in a treatment chamber of a plasma CVD apparatuswhich is vacuum-evacuated is held at a temperature higher than or equalto 180° C. and lower than or equal to 400° C., preferably higher than orequal to 200° C. and lower than or equal to 370° C., the pressure isgreater than or equal to 20 Pa and less than or equal to 250 Pa,preferably greater than or equal to 100 Pa and less than or equal to 250Pa with introduction of source gases into the treatment chamber, and ahigh-frequency power is supplied to an electrode provided in thetreatment chamber. Further, by setting the pressure in the treatmentchamber to be greater than or equal to 100 Pa and less than or equal to250 Pa, damage to the oxide semiconductor layer 304 can be reduced whenthe oxide insulating layer is formed.

A deposition gas containing silicon and an oxidizing gas are preferablyused as a source gas of the oxide insulating film. Typical examples ofthe deposition gas containing silicon include silane, disilane,trisilane, and silane fluoride. As the oxidizing gas, oxygen, ozone,dinitrogen monoxide, and nitrogen dioxide can be given as examples.

The insulating layer 307 can be formed by a sputtering method, a CVDmethod, or the like.

In the case of forming a silicon nitride film or a silicon nitride oxidefilm as the insulating layer 307, a deposition gas containing silicon,an oxidizing gas, and a gas containing nitrogen are preferably used as asource gas. Typical examples of the deposition gas containing siliconinclude silane, disilane, trisilane, and silane fluoride. As theoxidizing gas, oxygen, ozone, dinitrogen monoxide, and nitrogen dioxidecan be given as examples. As the gas containing nitrogen, nitrogen andammonia can be given as examples.

Through the above process, the transistor 300 can be formed.

<Another Structure Example of Transistor>

An example of the structure of a top-gate transistor to which the oxidesemiconductor layer of one embodiment of the present invention can beapplied will be described below.

Note that descriptions of components having structures or functionssimilar to those of the above, which are denoted by the same referencenumerals, are omitted below.

Structure Example

FIG. 11A is a schematic cross-sectional view of a top-gate transistor360.

The transistor 360 includes an oxide semiconductor layer 364 providedover the substrate 301 provided with an insulating layer 351, the sourceelectrode layer 305 a and the drain electrode layer 305 b which are incontact with the top surface of the oxide semiconductor layer 364, theinsulating layer 303 provided over the oxide semiconductor layer 364,and the source electrode layer 305 a and the drain electrode layer 305b, and the gate electrode layer 302 provided over the insulating layer303 to overlap with the oxide semiconductor layer 364. Moreover, aninsulating layer 352 covers the insulating layer 303 and the gateelectrode layer 302.

The oxide semiconductor layer of one embodiment of the present inventioncan be used as the oxide semiconductor layer 364 of the transistor 360.

For example, the oxide semiconductor layer 364 includes an oxidesemiconductor layer 364 a, an oxide semiconductor layer 364 b, and anoxide semiconductor layer 364 c. Here, an oxide semiconductor layerincluding a nanocrystal is used as each of the oxide semiconductor layer364 a and the oxide semiconductor layer 364 c. An oxide semiconductorlayer having higher film quality and a lower defect state density thanthe oxide semiconductor layer 364 a and the oxide semiconductor layer364 c is used as the oxide semiconductor layer 364 b. Preferably, aCAAC-OS film is used for the oxide semiconductor layer 364 b.

The insulating layer 351 has a function of suppressing diffusion ofimpurities from the substrate 301 to the oxide semiconductor layer 364.For example, a structure similar to that of the insulating layer 307 canbe employed. Note that the insulating layer 351 is not necessarilyprovided when not needed.

The insulating layer 352 can be formed using an insulating film having ablocking effect against oxygen, hydrogen, water, and the like in amanner similar to that of the insulating layer 307. Note that theinsulating layer 307 is not necessarily provided when not needed.

Modification Example

Structure examples of a transistor that is partly different from thetransistor 360 is described below.

FIG. 11B is a schematic cross-sectional view of a transistor 370. Thetransistor 370 differs from the transistor 360 in the structure of asource electrode layer and a drain electrode layer. Specifically, thetransistor 370 differs from the transistor 360 in that a sourceelectrode layer 306 a is formed over the source electrode layer 305 aand a drain electrode layer 306 b is formed over the drain electrodelayer 305 b.

As described above, in the case where a material with which an oxygenvacancy can be generated in the oxide semiconductor layer is used forthe source electrode layer 305 a and the drain electrode layer 305 b,oxygen vacancies are generated in and around a region of the oxidesemiconductor layer which is in contact with the source electrode layer305 a or the drain electrode layer 305 b, so that the region becomesn-type and the n-type region can serve as a source or drain region ofthe transistor.

However, in the case of forming a transistor with an extremely shortchannel length, the n-type region which is formed by generation of theoxygen vacancies sometimes extends in the channel length direction ofthe transistor. In that case, the following phenomena and the like occuras for the electrical characteristics of the transistor: the thresholdvoltage is fluctuated; the source region and the drain region arebrought into conduction so that on/off state of the transistor cannot becontrolled. Accordingly, when a transistor with an extremely shortchannel length is formed, it is not preferable that the conductivematerial which is easily bonded to oxygen be used for a source electrodelayer and a drain electrode layer.

For this reason, a distance between the source electrode layer 305 a andthe drain electrode layer 305 b illustrated as L1 in FIG. 11B is set to0.8 mm or more, preferably, 1.0 mm or more. When L1 is less than 0.8 μm,it is possible that an adverse effect of oxygen vacancies generated inthe channel formation region cannot be eliminated and electricalcharacteristics of the transistor are degraded. Note that L1 can beregarded as the shortest distance between the end portion of the sourceelectrode layer 305 a and the end portion of the drain electrode layer305 b which are in contact with the oxide semiconductor layer 364 andface each other. Note that in FIG. 11B, the n-type region is illustratedschematically with a dotted line.

Thus, in the transistor 370, the source electrode layer 306 a is formedin contact with the source electrode layer 305 a and the oxidesemiconductor layer 364, using a conductive material which is lesslikely to be bonded to oxygen. In addition, the drain electrode layer306 b is formed in contact with the drain electrode layer 305 b and theoxide semiconductor layer 364, using a conductive material which is lesslikely to be bonded to oxygen.

The source electrode layer 306 a extends in a direction of L1 beyond anend portion of the source electrode layer 305 a in contact with theoxide semiconductor layer 364, and the drain electrode layer 306 bextends in the direction of L1 beyond an end portion of the drainelectrode layer 305 b in contact with the oxide semiconductor layer 364.

The extended portion of the source electrode layer 306 a and theextended portion of the drain electrode layer 306 b are in contact withthe oxide semiconductor layer 364 (in particular, the oxidesemiconductor layer 364 c). In the transistor 370 illustrated in FIG.11B, a distance between an end portion of the extended portion of thesource electrode layer 306 a, the end portion being in contact with theoxide semiconductor layer 364 and an end portion of the extended portionof the drain electrode layer 306 b, the end portion being in contactwith the oxide semiconductor layer 364 corresponds to the channellength. The channel length is shown as L2 in FIG. 11B.

As the conductive material which is less likely to be bonded to oxygenand is used to form the source electrode layer 306 a and the drainelectrode layer 306 b, for example, a conductive nitride such astantalum nitride or titanium nitride, or ruthenium is preferably used.Note that the conductive material which is less likely to be bonded tooxygen includes, in its category, a material to which oxygen is lesslikely to be diffused. The thickness of the conductive material ispreferably greater than or equal to 5 nm and less than or equal to 500nm, further preferably greater than or equal to 10 nm and less than orequal to 300 nm, still further preferably greater than or equal to 10 nmand less than or equal to 100 nm.

With the use of the above conductive material which is less likely to bebonded to oxygen for the source electrode layer 306 a and the drainelectrode layer 306 b, generation of an oxygen vacancy in the channelformation region of the oxide semiconductor layer 364 can be suppressed,so that change of the channel formation region into an n-type can besuppressed. Accordingly, even a transistor with an extremely shortchannel length can have favorable electrical characteristics. That is,L2 can be made smaller than L1; for example, even when L2 is 30 nm orshorter, favorable electrical characteristics of the transistor can beobtained. Further, in the case where the width of a single crystalregion included in the oxide semiconductor layer 364 is 30 nm or more,the whole area of the channel formation region might be a single crystaloxide semiconductor layer in a cross section in the channel lengthdirection.

Note that the conductive nitride such as tantalum nitride or titaniumnitride might occlude hydrogen. Therefore, when conductive nitride isprovided in contact with the oxide semiconductor layer 364, the hydrogenconcentration in the oxide semiconductor layer 364 can be reduced.

Note that when a transistor with an extremely short channel length isformed, the source electrode layer 306 a and the drain electrode layer306 b may be formed in such a manner that resist masks are processed bya method suitable for thin line processing, such as an electron beamexposure, and then etching treatment is performed. Note that with theuse of a positive type resist for the resist masks, the exposed regioncan be minimized and throughput can be thus improved. In the abovemanner, a transistor with a channel length of 30 nm or less can beformed.

This embodiment can be combined as appropriate with any of the otherembodiments disclosed in this specification.

Embodiment 5

FIG. 12A illustrates an example of a circuit diagram of a NOR circuit,which is a logic circuit, as an example of the semiconductor device ofone embodiment of the present invention. FIG. 12B is a circuit diagramof a NAND circuit.

In the NOR circuit in FIG. 12A, p-channel transistors 801 and 802 aretransistors in each of which a channel formation region is formed usinga semiconductor material (e.g., silicon) other than an oxidesemiconductor, and n-channel transistors 803 and 804 each include anoxide semiconductor and each have a structure similar to any of thestructures of the transistors described in Embodiment 4.

A transistor including a semiconductor material such as silicon caneasily operate at high speed. In contrast, a charge can be held in atransistor including an oxide semiconductor for a long time owing to itscharacteristics.

To miniaturize the logic circuit, it is preferable that the n-channeltransistors 803 and 804 be stacked over the p-channel transistors 801and 802. For example, the transistors 801 and 802 can be formed using asingle crystal silicon substrate, and the transistors 803 and 804 can beformed over the transistors 801 and 802 with an insulating layerprovided therebetween.

In the NAND circuit in FIG. 12B, p-channel transistors 811 and 814 aretransistors in each of which a channel formation region is formed usinga semiconductor material (e.g., silicon) other than an oxidesemiconductor, and n-channel transistors 812 and 813 each include anoxide semiconductor layer and each have a structure similar to any ofthe structures of the transistors described in Embodiment 4.

Note that in the NAND circuit in FIG. 12B, the transistors 812 and 813have the structure similar to the transistor 360, and by controlling thepotential of the second gate electrode, for example, by setting thepotential to GND, the threshold voltages of the transistors 812 and 813are increased, so that the transistors can be normally off.

As in the NOR circuit in FIG. 12A, to miniaturize the logic circuit, itis preferable that the n-channel transistors 812 and 813 be stacked overthe p-channel transistors 811 and 812.

By applying a transistor including an oxide semiconductor for a channelformation region and having an extremely low off-state current to thesemiconductor device in this embodiment, power consumption of thesemiconductor device can be sufficiently reduced.

A semiconductor device which is miniaturized, is highly integrated, andhas stable and excellent electrical characteristics by stackingsemiconductor elements including different semiconductor materials and amethod for manufacturing the semiconductor device can be provided.

In addition, by employing the structure of the transistor including theoxide semiconductor layer of one embodiment of the present invention, aNOR circuit and a NAND circuit with high reliability and stablecharacteristics can be provided.

Note that although the NOR circuit and the NAND circuit including thetransistor described in Embodiment 3 are described as examples in thisembodiment, one embodiment of the present invention is not particularlylimited to the circuits, and an AND circuit, an OR circuit, or the likecan be formed using the transistor described in Embodiment 3.

Alternatively, it is possible to fabricate a display device by combininga display element with any of the transistors described in thisembodiment and the other embodiments. For example, a display element, adisplay device which is a device including a display element, alight-emitting element, and a light-emitting device which is a deviceincluding a light-emitting element can employ various modes and caninclude various elements. For example, a display medium, whose contrast,luminance, reflectivity, transmittance, or the like changes byelectromagnetic action, such as an EL (electroluminescence) element(e.g., an EL element including organic and inorganic materials, anorganic EL element, or an inorganic EL element), an LED (e.g., a whiteLED, a red LED, a green LED, or a blue LED), a transistor (a transistorwhich emits light depending on the amount of current), an electronemitter, a liquid crystal element, electronic ink, an electrophoreticelement, a grating light valve (GLV), a plasma display panel (PDP), adigital micromirror device (DMD), a piezoelectric ceramic display, or acarbon nanotube, can be used as a display element, a display device, alight-emitting element, or a light-emitting device. Note that example ofdisplay devices including EL elements include an EL display. Displaydevices having electron emitters include a field emission display (FED),an SED-type flat panel display (SED: surface-conduction electron-emitterdisplay), and the like. Examples of display devices including liquidcrystal elements include a liquid crystal display (e.g., a transmissiveliquid crystal display, a transflective liquid crystal display, areflective liquid crystal display, a direct-view liquid crystal display,or a projection liquid crystal display) and the like. Examples ofdisplay devices including electronic ink or electrophoretic elementsinclude electronic paper.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 6

In this embodiment, an example of a semiconductor device (memory device)which includes the transistor described in Embodiment 3, which canretain stored data even when not powered, and which has an unlimitednumber of write cycles will be described with reference to drawings.

FIG. 13A is a circuit diagram illustrating a semiconductor device ofthis embodiment.

A transistor including a semiconductor material (e.g., silicon) otherthan an oxide semiconductor can be used as a transistor 260 illustratedin FIG. 13A and thus the transistor 260 can easily operate at highspeed. Further, a structure similar to that of the transistor describedin Embodiment 4 which includes the oxide semiconductor layer of oneembodiment of the present invention can be employed for a transistor 262to enable charge to be held for a long time owing to itscharacteristics.

Although all the transistors are n-channel transistors here, p-channeltransistors can be used as the transistors used for the semiconductordevice described in this embodiment.

In FIG. 13A, a first wiring (1st Line) is electrically connected to asource electrode layer of the transistor 260. A second wiring (2nd Line)is electrically connected to a drain electrode layer of the transistor260. A third wiring (3rd Line) is electrically connected to one of asource electrode layer and a drain electrode layer of the transistor262, and a fourth wiring (4th Line) is electrically connected to a gateelectrode layer of the transistor 262. A gate electrode layer of thetransistor 260 and the other of the source electrode layer and the drainelectrode layer of the transistor 262 are electrically connected to oneelectrode of a capacitor 264. A fifth wiring (5th Line) is electricallyconnected to the other electrode of the capacitor 264.

The semiconductor device in FIG. 13A utilizes a characteristic in whichthe potential of the gate electrode layer of the transistor 260 can beheld, and thus enables writing, storing, and reading of data as follows.

Writing and storing of data are described. First, the potential of thefourth wiring is set to a potential at which the transistor 262 isturned on, so that the transistor 262 is turned on. Accordingly, thepotential of the third wiring is supplied to the gate electrode layer ofthe transistor 260 and the capacitor 264. That is, a predeterminedcharge is supplied to the gate electrode layer of the transistor 260(writing). Here, one of two kinds of charges providing differentpotential levels (hereinafter referred to as a low-level charge and ahigh-level charge) is supplied. After that, the potential of the fourthwiring is set to a potential at which the transistor 262 is turned off,so that the transistor 262 is turned off. Thus, the charge supplied tothe gate electrode layer of the transistor 260 is held (holding).

Since the off-state current of the transistor 262 is extremely low, thecharge of the gate electrode layer of the transistor 260 is held for along time.

Next, reading of data is described. By supplying an appropriatepotential (a reading potential) to the fifth wiring while supplying apredetermined potential (a constant potential) to the first wiring, thepotential of the second wiring varies depending on the amount of chargeheld in the gate electrode layer of the transistor 260. This is becausein general, when the transistor 260 is an n-channel transistor, anapparent threshold voltage V_(th) _(—) _(H) in the case where thehigh-level charge is given to the gate electrode layer of the transistor260 is lower than an apparent threshold voltage V_(th) _(—) _(L) in thecase where the low-level charge is given to the gate electrode layer ofthe transistor 260. Here, an apparent threshold voltage refers to thepotential of the fifth wiring which is needed to turn on the transistor260. Thus, the potential of the fifth wiring is set to a potential V₀which is between V_(th) _(—) _(H) and V_(th) _(—) _(L), whereby chargesupplied to the gate electrode layer of the transistor 260 can bedetermined. For example, in the case where the high-level charge issupplied in writing, when the potential of the fifth wiring is V₀(>V_(th) _(—) _(H)), the transistor 260 is turned on. In the case wherethe low-level charge is supplied in writing, even when the potential ofthe fifth wiring is V₀ (<V_(th) _(—) _(L)), the transistor 260 remainsoff. Therefore, the stored data can be read by the potential of thesecond wiring.

Note that in the case where memory cells are arrayed, it is necessarythat only data of a desired memory cell be able to be read. The fifthwiring in the case where data is not read may be supplied with apotential at which the transistor 260 is turned off regardless of thestate of the gate electrode layer, that is, a potential lower thanV_(th) _(—) _(H). Alternatively, the fifth wiring may be supplied with apotential at which the transistor 260 is turned on regardless of thestate of the gate electrode layer, that is, a potential higher thanV_(th) _(—) _(L).

FIG. 13B illustrates another example of one embodiment of the structureof the storage device. FIG. 13B illustrates an example of a circuitconfiguration of the semiconductor device, and FIG. 13C is a conceptualdiagram illustrating an example of the semiconductor device. First, thesemiconductor device illustrated in FIG. 13B is described, and then thesemiconductor device illustrated in FIG. 13C is described.

In the semiconductor device illustrated in FIG. 13B, a bit line BL iselectrically connected to the source electrode or the drain electrode ofthe transistor 262, a word line WL is electrically connected to the gateelectrode layer of the transistor 262, and the source electrode or thedrain electrode of the transistor 262 is electrically connected to afirst terminal of a capacitor 254.

Here, the transistor 262 including an oxide semiconductor has anextremely low off-state current. For that reason, a potential of thefirst terminal of the capacitor 254 (or a charge accumulated in thecapacitor 254) can be held for an extremely long time by turning off thetransistor 262.

Next, writing and holding of data in the semiconductor device (a memorycell 250) illustrated in FIG. 13B are described.

First, the potential of the word line WL is set to a potential at whichthe transistor 262 is turned on, and the transistor 262 is turned on.Accordingly, the potential of the bit line BL is supplied to the firstterminal of the capacitor 254 (writing). After that, the potential ofthe word line WL is set to a potential at which the transistor 262 isturned off, so that the transistor 262 is turned off. Thus, thepotential of the first terminal of the capacitor 254 is held (holding).

Since the transistor 262 has an extremely low off-state current, thepotential of the first terminal of the capacitor 254 (or a chargeaccumulated in the capacitor 254) can be held for an extremely longtime.

Next, reading of data is described. When the transistor 262 is turnedon, the bit line BL which is in a floating state and the capacitor 254are electrically connected to each other, and the charge isredistributed between the bit line BL and the capacitor 254. As aresult, the potential of the bit line BL is changed. The amount ofchange in potential of the bit line BL varies depending on the potentialof the first terminal of the capacitor 254 (or the charge accumulated inthe capacitor 254).

For example, the potential of the bit line BL after chargeredistribution is (C_(B)×V_(B0)+C×V)/(C_(B)+C), where V is the potentialof the first terminal of the capacitor 254, C is the capacitance of thecapacitor 254, C_(B) is the capacitance component of the bit line BL(hereinafter also referred to as bit line capacitance), and V_(BO) isthe potential of the bit line BL before the charge redistribution.Therefore, it can be found that assuming that the memory cell 250 is ineither of two states in which the potentials of the first terminal ofthe capacitor 254 are V₁ and V₀ (V₁>V₀), the potential of the bit lineBL in the case of holding the potential V₁(=(C_(B)×V_(BO)+C×V₁)/(C_(B)+C)) is higher than the potential of the bitline BL in the case of holding the potential V₀(=(C_(B)×V_(B0)+C×V₀)/(C_(B)+C)).

Then, by comparing the potential of the bit line BL with a predeterminedpotential, data can be read.

As described above, the semiconductor device illustrated in FIG. 13B canhold charge that is accumulated in the capacitor 254 for a long timebecause the off-state current of the transistor 262 is extremely low. Inother words, refresh operation becomes unnecessary or the frequency ofthe refresh operation can be extremely low, which leads to a sufficientreduction in power consumption. Moreover, stored data can be retainedfor a long period even when power is not supplied.

Next, the semiconductor device illustrated in FIG. 13C is described.

The semiconductor device illustrated in FIG. 13C includes a memory cellarray 251 (memory cell arrays 251 a and 251 b) including the pluralityof memory cells 250 illustrated in FIG. 13B as memory circuits in theupper portion, and a peripheral circuit 253 in the lower portion whichis necessary for operating the memory cell array 251. Note that theperipheral circuit 253 is electrically connected to the memory cellarray 251.

In the structure illustrated in FIG. 13C, the peripheral circuit 253 canbe provided directly under the memory cell array 251 (the memory cellarrays 251 a and 251 b). Thus, the size of the semiconductor device canbe reduced.

It is preferable that a semiconductor material of the transistorprovided in the peripheral circuit 253 be different from that of thetransistor 262. For example, silicon, germanium, silicon germanium,silicon carbide, or gallium arsenide can be used, and a single crystalsemiconductor is preferably used. Alternatively, an organicsemiconductor material or the like may be used. A transistor includingsuch a semiconductor material can operate at sufficiently high speed.Thus, the transistor enables a variety of circuits (e.g., a logiccircuit and a driver circuit) which need to operate at high speed to befavorably obtained.

Note that FIG. 13C illustrates, as an example, the semiconductor devicein which two memory cell arrays 251 (the memory cell arrays 251 a and251 b) are stacked; however, the number of stacked memory cell arrays isnot limited to two. Three or more memory cells arrays may be stacked.

When a transistor including the oxide semiconductor layer of oneembodiment of the present invention in a channel formation region isused as the transistor 262, stored data can be retained for a longperiod. In other words, refresh operation becomes unnecessary or thefrequency of the refresh operation in a semiconductor memory device canbe extremely low, which leads to a sufficient reduction in powerconsumption.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 7

In this embodiment, a structure of a display panel of one embodiment ofthe present invention will be described with reference to FIGS. 14A to14C.

FIG. 14A is a top view of the display panel of one embodiment of thepresent invention. FIG. 14B is a circuit diagram illustrating a pixelcircuit that can be used in the case where a liquid crystal element isused in a pixel in the display panel of one embodiment of the presentinvention. FIG. 14C is a circuit diagram illustrating a pixel circuitthat can be used in the case where an organic EL element is used in apixel in the display panel of one embodiment of the present invention.

The transistor in the pixel portion can be formed in accordance withEmbodiment 3. Further, the transistor can be easily formed as ann-channel transistor, and thus part of a driver circuit that can beformed using an n-channel transistor can be formed over the samesubstrate as the transistor of the pixel portion. With the use of thetransistor described in Embodiment 3 for the pixel portion or the drivercircuit in this manner, a highly reliable display device can beprovided.

FIG. 14A illustrates an example of a block diagram of an active matrixdisplay device. A pixel portion 501, a first scan line driver circuit502, a second scan line driver circuit 503, and a signal line drivercircuit 504 are provided over a substrate 500 in the display device. Inthe pixel portion 501, a plurality of signal lines extended from thesignal line driver circuit 504 are arranged and a plurality of scanlines extended from the first scan line driver circuit 502 and thesecond scan line driver circuit 503 are arranged. Note that pixels whichinclude display elements are provided in a matrix in respective regionswhere the scan lines and the signal lines intersect with each other. Thesubstrate 500 of the display device is connected to a timing controlcircuit (also referred to as a controller or a controller IC) through aconnection portion such as a flexible printed circuit (FPC).

In FIG. 14A, the first scan line driver circuit 502, the second scanline driver circuit 503, and the signal line driver circuit 504 areformed over the same substrate 500 as the pixel portion 501.Accordingly, the number of components which are provided outside, suchas a driver circuit, can be reduced, so that a reduction in cost can beachieved. Further, in the case where the driver circuit is providedoutside the substrate 500, wirings would need to be extended and thenumber of connections of wirings would be increased, but when the drivercircuit is provided over the substrate 500, the number of connections ofthe wirings can be reduced. Consequently, an improvement in reliabilityor yield can be achieved.

<Liquid Crystal Panel>

FIG. 14B illustrates an example of a circuit configuration of the pixel.Here, a pixel circuit which is applicable to a pixel of a VA liquidcrystal display panel is illustrated.

This pixel circuit can be applied to a structure in which one pixelincludes a plurality of pixel electrode layers. The pixel electrodelayers are connected to different transistors, and the transistors canbe driven with different gate signals. Accordingly, signals applied toindividual pixel electrode layers in a multi-domain pixel can becontrolled independently.

A gate wiring 512 of a transistor 516 and a gate wiring 513 of atransistor 517 are separated so that different gate signals can besupplied thereto. In contrast, a source or drain electrode layer 514that functions as a data line is shared by the transistors 516 and 517.The transistor described in Embodiment 3 can be used as appropriate aseach of the transistors 516 and 517. Thus, a highly reliable liquidcrystal display panel can be provided.

The shapes of a first pixel electrode layer electrically connected tothe transistor 516 and a second pixel electrode layer electricallyconnected to the transistor 517 are described. The first pixel electrodelayer and the second pixel electrode layer are separated by a slit. Thefirst pixel electrode layer is spread in a V shape and the second pixelelectrode layer is provided so as to surround the first pixel electrodelayer.

A gate electrode layer of the transistor 516 is connected to the gatewiring 512, and a gate electrode layer of the transistor 517 isconnected to the gate wiring 513. When different gate signals aresupplied to the gate wiring 512 and the gate wiring 513, operationtimings of the transistor 516 and the transistor 517 can be varied. As aresult, alignment of liquid crystals can be controlled.

Further, a storage capacitor may be formed using a capacitor wiring 510,a gate insulating layer that functions as a dielectric, and a capacitorelectrode electrically connected to the first pixel electrode layer orthe second pixel electrode layer.

The multi-domain pixel includes a first liquid crystal element 518 and asecond liquid crystal element 519. The first liquid crystal element 518includes the first pixel electrode layer, a counter electrode layer, anda liquid crystal layer therebetween. The second liquid crystal element519 includes the second pixel electrode layer, a counter electrodelayer, and a liquid crystal layer therebetween.

Note that a pixel circuit of the present invention is not limited tothat shown in FIG. 14B. For example, a switch, a resistor, a capacitor,a transistor, a sensor, a logic circuit, or the like may be added to thepixel illustrated in FIG. 14B.

<Organic EL Panel>

FIG. 14C illustrates another example of a circuit configuration of thepixel. Here, a pixel structure of a display panel including an organicEL element is shown.

In an organic EL element, by application of voltage to a light-emittingelement, electrons are injected from one of a pair of electrodes andholes are injected from the other of the pair of electrodes, into alayer containing a light-emitting organic compound; thus, current flows.The electrons and holes are recombined, and thus, the light-emittingorganic compound is excited. The light-emitting organic compound returnsto a ground state from the excited state, thereby emitting light. Owingto such a mechanism, this light-emitting element is referred to as acurrent-excitation light-emitting element.

FIG. 14C illustrates an applicable example of a pixel circuit. Here, onepixel includes two n-channel transistors. Note that the oxidesemiconductor layer of one embodiment of the present invention can beused for channel formation regions of the n-channel transistors.Further, digital time grayscale driving can be employed for the pixelcircuit.

The configuration of the applicable pixel circuit and operation of apixel employing digital time grayscale driving are described.

A pixel 520 includes a switching transistor 521, a driver transistor522, a light-emitting element 524, and a capacitor 523. A gate electrodelayer of the switching transistor 521 is connected to a scan line 526, afirst electrode (one of a source electrode layer and a drain electrodelayer) of the switching transistor 521 is connected to a signal line525, and a second electrode (the other of the source electrode layer andthe drain electrode layer) of the switching transistor 521 is connectedto a gate electrode layer of the driver transistor 522. The gateelectrode layer of the driver transistor 522 is connected to a powersupply line 527 through the capacitor 523, a first electrode of thedriver transistor 522 is connected to the power supply line 527, and asecond electrode of the driver transistor 522 is connected to a firstelectrode (a pixel electrode) of the light-emitting element 524. Asecond electrode of the light-emitting element 524 corresponds to acommon electrode 528. The common electrode 528 is electrically connectedto a common potential line formed over the same substrate as the commonelectrode 528.

As the switching transistor 521 and the driver transistor 522, thetransistor described in Embodiment 3 can be used as appropriate. In thismanner, a highly reliable organic EL display panel can be provided.

The potential of the second electrode (the common electrode 528) of thelight-emitting element 524 is set to be a low power supply potential.Note that the low power supply potential is lower than a high powersupply potential supplied to the power supply line 527. For example, thelow power supply potential can be GND, 0V, or the like. The high powersupply potential and the low power supply potential are set to be higherthan or equal to the forward threshold voltage of the light-emittingelement 524, and the difference between the potentials is applied to thelight-emitting element 524, whereby current is supplied to thelight-emitting element 524, leading to light emission. The forwardvoltage of the light-emitting element 524 refers to a voltage at which adesired luminance is obtained, and is at least higher than a forwardthreshold voltage.

Note that gate capacitance of the driver transistor 522 may be used as asubstitute for the capacitor 523, so that the capacitor 523 can beomitted. The gate capacitance of the driver transistor 522 may be formedbetween the channel formation region and the gate electrode layer.

Next, a signal input to the driver transistor 522 is described. In thecase of a voltage-input voltage driving method, a video signal forsubstantially turning on or off the driver transistor 522 is input tothe driver transistor 522. In order for the driver transistor 522 tooperate in a linear region, voltage higher than the voltage of the powersupply line 527 is applied to the gate electrode layer of the drivertransistor 522. Note that voltage greater than or equal to voltage whichis the sum of power supply line voltage and the threshold voltage V_(th)of the driver transistor 522 is applied to the signal line 525.

In the case of performing analog grayscale driving, a voltage greaterthan or equal to a voltage which is the sum of the forward voltage ofthe light-emitting element 524 and the threshold voltage V_(th) of thedriver transistor 522 is applied to the gate electrode layer of thedriver transistor 522. A video signal by which the driver transistor 522is operated in a saturation region is input, so that current is suppliedto the light-emitting element 524. In order for the driver transistor522 to operate in a saturation region, the potential of the power supplyline 527 is set higher than the gate potential of the driver transistor522. When an analog video signal is used, it is possible to supplycurrent to the light-emitting element 524 in accordance with the videosignal and perform analog grayscale driving.

Note that the configuration of the pixel circuit of the presentinvention is not limited to that shown in FIG. 14C. For example, aswitch, a resistor, a capacitor, a sensor, a transistor, a logiccircuit, or the like may be added to the pixel circuit illustrated inFIG. 14C.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 8

In this embodiment, structures of a semiconductor device including theoxide semiconductor layer of one embodiment of the present invention andelectronic devices will be described with reference to FIG. 15 and FIGS.16A to 16D.

FIG. 15 is a block diagram of an electronic device including thesemiconductor device to which the oxide semiconductor layer of oneembodiment of the present invention is applied.

FIGS. 16A to 16D are external views of electronic devices each includingthe semiconductor device to which the oxide semiconductor layer of oneembodiment of the present invention is applied.

An electronic device illustrated in FIG. 15 includes an RF circuit 901,an analog baseband circuit 902, a digital baseband circuit 903, abattery 904, a power supply circuit 905, an application processor 906, aflash memory 910, a display controller 911, a memory circuit 912, adisplay 913, a touch sensor 919, an audio circuit 917, a keyboard 918,and the like.

The application processor 906 includes a CPU 907, a DSP 908, and aninterface (IF) 909. Moreover, the memory circuit 912 can include an SRAMor a DRAM.

The transistor described in Embodiment 3 is applied to the memorycircuit 912, whereby a highly reliable electronic device which can writeand read data can be provided.

The transistor described in Embodiment 3 is applied to a register or thelike included in the CPU 907 or the DSP 908, whereby a highly reliableelectronic device which can write and read data can be provided.

Note that in the case where the off-state leakage current of thetransistor described in Embodiment 3 is extremely low, the memorycircuit 912 can retain stored data for a long period and can havesufficiently reduced power consumption. Moreover, the CPU 907 or the DSP908 can store the state before power gating in a register or the likeduring a period in which the power gating is performed.

Further, the display 913 includes a display portion 914, a source driver915, and a gate driver 916.

The display portion 914 includes a plurality of pixels arranged in amatrix. The pixel includes a pixel circuit, and the pixel circuit iselectrically connected to the gate driver 916.

The transistor described in Embodiment 3 can be used as appropriate inthe pixel circuit or the gate driver 916. Accordingly, a highly reliabledisplay can be provided.

Examples of electronic devices are a television set (also referred to asa television or a television receiver), a monitor of a computer or thelike, a camera such as a digital camera or a digital video camera, adigital photo frame, a mobile phone handset (also referred to as amobile phone or a mobile phone device), a portable game machine, aportable information terminal, an audio reproducing device, alarge-sized game machine such as a pachinko machine, and the like.

FIG. 16A illustrates a portable information terminal, which includes amain body 1101, a housing 1102, a display portion 1103 a, a displayportion 1103 b, and the like. The display portion 1103 b includes atouch panel. By touching a keyboard button 1104 displayed on the displayportion 1103 b, screen operation can be carried out, and text can beinput. Needless to say, the display portion 1103 a may functions as atouch panel. A liquid crystal panel or an organic light-emitting panelis manufactured by using the transistor described in Embodiment 3 as aswitching element and applied to the display portion 1103 a or 1103 b,whereby a highly reliable portable information terminal can be provided.

The portable information terminal illustrated in FIG. 16A can have afunction of displaying a variety of kinds of data (e.g., a still image,a moving image, and a text image), a function of displaying a calendar,a date, the time, or the like on the display portion, a function ofoperating or editing data displayed on the display portion, a functionof controlling processing by a variety of kinds of software (programs),and the like. Further, an external connection terminal (an earphoneterminal, a USB terminal, or the like), a recording medium insertionportion, or the like may be provided on the back surface or the sidesurface of the housing.

The portable information terminal illustrated in FIG. 16A may transmitand receive data wirelessly. Through wireless communication, desiredbook data or the like can be purchased and downloaded from an electronicbook server.

FIG. 16B illustrates a portable music player, which includes in a mainbody 1021, a display portion 1023, a fixing portion 1022 with which theportable music player can be worn on the ear, a speaker, an operationbutton 1024, an external memory slot 1025, and the like. A liquidcrystal panel or an organic light-emitting panel is manufactured byusing the transistor described in Embodiment 3 as a switching elementand applied to the display portion 1023, whereby a highly reliableportable music player can be provided.

Furthermore, when the portable music player illustrated in FIG. 16B hasan antenna, a microphone function, or a wireless communication functionand is used with a mobile phone, a user can talk on the phone wirelesslyin a hands-free way while driving a car or the like.

FIG. 16C illustrates a mobile phone, which includes two housings, ahousing 1030 and a housing 1031. The housing 1031 includes a displaypanel 1032, a speaker 1033, a microphone 1034, a pointing device 1036, acamera lens 1037, an external connection terminal 1038, and the like.The housing 1030 is provided with a solar cell 1040 for charging themobile phone, an external memory slot 1041, and the like. In addition,an antenna is incorporated in the housing 1031. The transistor describedin Embodiment 3 is applied to the display panel 1032, whereby a highlyreliable mobile phone can be provided.

Further, the display panel 1032 includes a touch panel. A plurality ofoperation keys 1035 which are displayed as images are indicated bydotted lines in FIG. 16C. Note that a boosting circuit by which avoltage output from the solar cell 1040 is increased so as to besufficiently high for each circuit is also included.

For example, a power transistor used for a power supply circuit such asa boosting circuit can also be formed when the oxide semiconductor layerof the transistor described in the Embodiment 3 has a thickness greaterthan or equal to 2 μm and less than or equal to 50 μm.

In the display panel 1032, the direction of display is changed asappropriate depending on the application mode. Further, the mobile phoneis provided with the camera lens 1037 on the same surface as the displaypanel 1032, and thus it can be used as a video phone. The speaker 1033and the microphone 1034 can be used for videophone calls, recording, andplaying sound, and the like as well as voice calls. Moreover, thehousings 1030 and 1031 in a state where they are developed asillustrated in FIG. 16C can shift, by sliding, to a state where one islapped over the other. Therefore, the size of the mobile phone can bereduced, which makes the mobile phone suitable for being carried around.

The external connection terminal 1038 can be connected to an AC adaptorand a variety of cables such as a USB cable, whereby charging and datacommunication with a personal computer or the like are possible.Further, by inserting a recording medium into the external memory slot1041, a larger amount of data can be stored and moved.

Further, in addition to the above functions, an infrared communicationfunction, a television reception function, or the like may be provided.

FIG. 16D illustrates an example of a television set. In a television set1050, a display portion 1053 is incorporated in a housing 1051. Imagescan be displayed on the display portion 1053. Moreover, a CPU isincorporated in a stand 1055 for supporting the housing 1051. Thetransistor described in Embodiment 3 is applied to the display portion1053 and the CPU, whereby the television set 1050 can have highreliability.

The television set 1050 can be operated with an operation switch of thehousing 1051 or a separate remote controller. Further, the remotecontroller may be provided with a display portion for displaying dataoutput from the remote controller.

Note that the television set 1050 is provided with a receiver, a modem,and the like. With the use of the receiver, the television set 1050 canreceive general TV broadcasts. Moreover, when the television set 1050 isconnected to a communication network with or without wires via themodem, one-way (from a sender to a receiver) or two-way (between asender and a receiver or between receivers) information communicationcan be performed.

Further, the television set 1050 is provided with an external connectionterminal 1054, a storage medium recording and reproducing portion 1052,and an external memory slot. The external connection terminal 1054 canbe connected to various types of cables such as a USB cable, wherebydata communication with a personal computer or the like is possible. Adisk storage medium is inserted into the storage medium recording andreproducing portion 1052, and data stored in the storage medium can beread and data can be written to the storage medium. In addition, animage, a video, or the like stored as data in an external memory 1056inserted into the external memory slot can be displayed on the displayportion 1053.

Further, in the case where the off-state leakage current of thetransistor described in Embodiment 3 is extremely low, when thetransistor is applied to the external memory 1056 or the CPU, thetelevision set 1050 can have high reliability and sufficiently reducedpower consumption.

Example 1

In this example, a nanocrystal included in the oxide semiconductor layerof one embodiment of the present invention will be described below withan electron diffraction pattern of a nanocrystalline oxide semiconductorfilm.

An electron diffraction pattern obtained by electron diffraction with abeam diameter of 10 nmφ or less (nanobeam electron diffraction) of ananocrystalline oxide semiconductor film is neither a halo patternindicating an amorphous state nor a pattern with spots having regularityindicating a crystalline state in which crystals are aligned with aspecific plane. That is, the nanocrystalline oxide semiconductor film isan oxide semiconductor film whose electron diffraction pattern has spotsnot having directionality.

FIG. 17A is a cross-sectional transmission electron microscopy (TEM)image of a nanocrystalline oxide semiconductor film. FIGS. 17B, 17C, and17D show electron diffraction patterns obtained by nanobeam electrondiffraction performed on Points 1, 2, 3 in FIG. 17A, respectively.

A sample in which an In—Ga—Zn-based oxide film was formed, as an exampleof the nanocrystalline oxide semiconductor film in FIGS. 17A to 17D,over a quartz glass substrate to a thickness of 50 nm was used. Thenanocrystalline oxide semiconductor film shown in FIGS. 17A to 17D wasformed under the following conditions: an oxide target containing In,Ga, and Zn at an atomic ratio of 1:1:1 was used, the atmosphere was anoxygen atmosphere (flow rate of 45 sccm), the pressure was 0.4 Pa, adirect current (DC) power of 0.5 kW was applied, and the substratetemperature was room temperature. Then, the width of the formednanocrystalline oxide semiconductor film was reduced to 100 nm or less(e.g., 40 nm±10 nm), and a cross-sectional TEM image and nanobeamelectron diffraction patterns were obtained.

FIG. 17A is the cross-sectional TEM image of the nanocrystalline oxidesemiconductor film which was taken with a transmission electronmicroscope (“H-9000NAR” manufactured by Hitachi High-TechnologiesCorporation) at an acceleration voltage of 300 kV and at a magnificationof 2,000,000 times. FIGS. 17B to 17D show the electron diffractionpatterns obtained by nanobeam electron diffraction with a beam diameterof about 1 nmφ, with a transmission electron microscope (“HF-2000”manufactured by Hitachi High-Technologies Corporation) at anacceleration voltage of 200 kV. Note that the measurement area of thenanobeam electron diffraction with a beam diameter of about 1 nmφ isgreater than or equal to 5 nmφ and less than or equal to 10 nmφ.

As shown in FIG. 17B, in the nanobeam electron diffraction pattern ofthe nanocrystalline oxide semiconductor film, a plurality ofcircumferentially arranged spots (bright points) are observed. In otherwords, in the pattern of the nanocrystalline oxide semiconductor film, aplurality of circumferentially (concentrically) distributed spots areobserved, or a plurality of circumferentially distributed spots form aplurality of concentric circles.

In FIG. 17C showing the central portion of the nanocrystalline oxidesemiconductor film in the thickness direction and in FIG. 17D showingthe vicinity of an interface between the nanocrystalline oxidesemiconductor film and the quartz glass substrate, a plurality ofcircumferentially distributed spots are observed as in FIG. 17B. In FIG.17C, a radius to a first circumference (the distance from a main spot)is in a range from 3.88 /nm to 4.93 /mm, or from 0.203 nm to 0.257 nmwhen converted into interplanar spacing.

The nanobeam electron diffraction patterns shown in FIGS. 17B to 17Dindicate that the nanocrystalline oxide semiconductor film includes aplurality of crystal parts whose surface orientations are random andwhose sizes are different from each other.

FIG. 18A is a plane TEM image of a nanocrystalline oxide semiconductorfilm. FIG. 18B shows an electron diffraction pattern obtained byselected-area electron diffraction performed on a region surrounded by acircle in FIG. 18A.

A sample in which an In—Ga—Zn-based oxide film was formed, as an exampleof the nanocrystalline oxide semiconductor film shown in FIGS. 18A and18B, over a quartz glass substrate to a thickness of 30 nm was used. Thenanocrystalline oxide semiconductor film shown in FIGS. 18A and 18B wasformed under the following conditions: an oxide target containing In,Ga, and Zn at an atomic ratio of 1:1:1 was used, the atmosphere was anoxygen atmosphere (flow rate of 45 sccm), the pressure was 0.4 Pa, adirect current (DC) power of 0.5 kW was applied, and the substratetemperature was room temperature. Then, the sample was thinned, and theplane TEM image and the selected-area electron diffraction pattern ofthe nanocrystalline oxide semiconductor film were obtained.

FIG. 18A is the plane TEM image of the nanocrystalline oxidesemiconductor film which was taken with a transmission electronmicroscope (“H-9000NAR” manufactured by Hitachi High-TechnologiesCorporation) at an acceleration voltage of 300 kV and at a magnificationof 500,000 times. FIG. 18B is the electron diffraction pattern obtainedby electron diffraction with a selected area of 300 nmφ. Note that themeasurement area is greater than or equal to 300 nmφ in consideration ofelectron beam expansion.

As shown in FIG. 18B, the electron diffraction pattern of thenanocrystalline oxide semiconductor film which was obtained byselected-area electron diffraction the measurement area of which iswider than that of the nanobeam electron diffraction is a halo pattern,in which the plurality of spots observed by the nanobeam electrondiffraction are not observed.

FIGS. 19A to 19C conceptually show diffraction intensity distribution inthe electron diffraction patterns shown in FIGS. 17B to 17D and FIG.18B. FIG. 19A is a conceptual diagram showing diffraction intensitydistribution in the nanobeam electron diffraction patterns shown inFIGS. 17B to 17D. FIG. 19B is a conceptual diagram showing diffractionintensity distribution in the selected-area electron diffraction patternshown in FIG. 18B. FIG. 19C is a conceptual diagram showing diffractionintensity distribution in an electron diffraction pattern of a singlecrystal structure or a polycrystalline structure.

In each of FIGS. 19A to 19C, the vertical axis represents the electrondiffraction intensity (arbitrary unit) indicating distribution of spotsor the like and the horizontal axis represents the distance from a mainspot.

In FIG. 19C for the single crystal structure or the polycrystallinestructure, peaks are observed at specific distances from the main spot,which are based on interplanar spacing (d value) between planes withwhich crystal parts are aligned.

As shown in each of FIGS. 17B to 17D, a circumferential region formed bythe plurality of spots observed in the nanobeam electron diffractionpattern of the nanocrystalline oxide semiconductor film has a relativelylarge width. Thus, FIG. 19A shows discrete distribution. Further, in thenanobeam electron diffraction pattern, a region with high luminanceformed by spots which are not clear is observed in a region betweenconcentric circles.

Further, the electron diffraction intensity distribution in theselected-area electron diffraction pattern of the nanocrystalline oxidesemiconductor film is continuous as shown in FIG. 19B. Since FIG. 19Bcan approximate a result obtained by widely observing the electrondiffraction intensity distribution shown in FIG. 19A, the continuousintensity distribution can be considered to result from the overlappingand connection of the plurality of spots.

FIGS. 19A to 19C indicate that the nanocrystalline oxide semiconductorfilm includes a plurality of crystal parts whose surface orientationsare random and whose sizes are different from each other and that thecrystal parts are so minute that spots are not observed in theselected-area electron diffraction pattern.

In FIGS. 17B to 17D in which the plurality of spots are observed, thewidth of the nanocrystalline oxide semiconductor film is 50 nm or less.Further, since the diameter of the electron beam was reduced to 1 nmφ,the measurement area is greater than or equal to 5 nm and less than orequal to 10 nm. Thus, it is assumed that the diameter of the crystalpart included in the nanocrystalline oxide semiconductor film is 50 nmor less, for example, 10 nm or less or 5 nm or less.

FIG. 20 shows a nanobeam electron diffraction pattern of a quartz glasssubstrate. The measurement conditions were similar to those for theelectron diffraction patterns shown in FIGS. 17B to 17D.

As shown in FIG. 20, the nanobeam electron diffraction pattern of thequartz glass substrate having an amorphous structure is a halo patternwithout specific spots in which the luminance is gradually changed forma main spot. This means that a plurality of circumferentiallydistributed spots like those observed in the pattern of thenanocrystalline oxide semiconductor film are not observed in the patternof a film having an amorphous structure even when electron diffractionis performed on a minute region. This indicates that the plurality ofcircumferentially distributed spots observed in FIGS. 17B to 17D arepeculiar to the nanocrystalline oxide semiconductor film.

FIG. 21 shows an electron diffraction pattern obtained after one-minuteirradiation of Point 2 in FIG. 17A with an electron beam whose diameterwas reduced to about 1 nmφ.

As in the electron diffraction pattern shown in FIG. 17C, a plurality ofcircumferentially distributed spots are observed in the electrondiffraction pattern shown in FIG. 21, and there is no significantdifference from FIG. 17C. This means that the crystal part observed inthe electron diffraction pattern shown in FIG. 17C existed at the timeof the formation of the oxide semiconductor film and did not result fromirradiation with the electron beam with the reduced diameter.

FIGS. 22A and 22B are enlarged images of portions in the cross-sectionalTEM image of FIG. 17A. FIG. 22A is a cross-sectional TEM image of thevicinity of Point 1 (the surface of the nanocrystalline oxidesemiconductor film) in FIG. 17A, which was observed at an observationmagnification of 8,000,000 times. FIG. 22B is a cross-sectional TEMimage of the vicinity of Point 2 (the central portion of thenanocrystalline oxide semiconductor film in the thickness direction) inFIG. 17A, which was observed at an observation magnification of8,000,000 times.

According to each of the TEM images of FIGS. 22A and 22B, a crystallinestructure cannot be clearly observed in the nanocrystalline oxidesemiconductor film.

The samples for the electron diffraction patterns shown in FIGS. 17A to17D and FIGS. 18A and 18B, in each of which the nanocrystalline oxidesemiconductor film of this embodiment was formed over the quartz glasssubstrate, were analyzed by X-ray diffraction (XRD). FIG. 23 shows anXRD spectrum of the samples measured by an out-of-plane method.

In FIG. 23, the vertical axis represents the X-ray diffraction intensity(arbitrary unit) and the horizontal axis represents the diffractionangle 2θ (degree). Note that the XRD spectrum was measured with an X-raydiffractometer, D8 ADVANCE manufactured by Bruker AXS.

As shown in FIG. 23, a peak corresponding to quartz is observed ataround 2θ=20° to 23°; however, a peak corresponding to the crystal partincluded in the nanocrystalline oxide semiconductor film cannot beobserved.

The results in FIGS. 22A and 22B and FIG. 23 also indicate that thecrystal part included in the nanocrystalline oxide semiconductor film isminute.

As described above, in the case of the nanocrystalline oxidesemiconductor film of this example, a peak indicating an orientation wasnot observed by X-ray diffraction (XRD) analysis the measurement area ofwhich is wide and the electron diffraction pattern obtained byselected-area electron diffraction the measurement area of which is wideis a halo pattern. This indicates that the nanocrystalline oxidesemiconductor film of this example is macroscopically equivalent to afilm having disordered atomic arrangement. However, spots (brightpoints) can be observed in the nanobeam electron diffraction pattern ofthe nanocrystalline oxide semiconductor film which was obtained bynanobeam electron diffraction in which the diameter of an electron beamis sufficiently small (e.g., 10 nmφ or less). Thus, it can be assumedthat the nanocrystalline oxide semiconductor film of this example is afilm in which minute crystal parts having random surface orientations(e.g., crystal parts each with a diameter of 10 nm or less, 5 nm orless, or 3 nm or less) cohere. A nanocrystal region including the minutecrystal parts is included in the entire region of the nanocrystallineoxide semiconductor film in the thickness direction.

Example 2

In this example, the adverse effect of an impurity in an oxidesemiconductor layer on crystallinity of the oxide semiconductor layerwas calculated.

In this example, hydrogen was assumed as an impurity contained in anoxide semiconductor layer, and a correlation between the amount ofhydrogen added to the oxide semiconductor layer and the orderliness ofthe oxide semiconductor layer to which hydrogen was added was calculatedby first-principles calculation.

As the oxide semiconductor layer, an In—Ga—Zn oxide in which an atomicratio of In to Ga and Zn is 1:1:1 was used. First, after the structuresof 28 atoms shown in FIG. 24 were optimized, the lengths of the a-axisand b-axis were made twice so that a lattice including 112 atoms wasobtained. Then, a difference between a structure in which hydrogen (H)was added to the lattice including the 112 atoms and a structure inwhich hydrogen (H) was not added to the lattice including the 112 atomswas examined in such manner that a temperature of each structure ischanged and the movement of each atom of the respective structures wascalculated.

In the structure in which hydrogen was added in this example, 4 hydrogenatoms (hydrogen concentration of 3.45 atom %) or 8 hydrogen atoms(hydrogen concentration of 6.67 atom %) were added to the latticeincluding the 112 atoms of the In—Ga—Zn oxide in which an atomic ratioof In to Ga and Zn is 1:1:1. Here, the added hydrogen atoms werearranged in a lattice of a perfect crystal.

The classical molecular dynamics calculation was carried out on thestructure in which a hydrogen atom was not added, the structure in which4 hydrogen atoms were added, and the structure in which 8 hydrogen atomswere added, which were then analyzed by the radial distribution functionto examine how the bonding strength in the In—Ga—Zn oxide to whichhydrogen was added was changed and how the structure thereof wasdisordered. The calculation conditions are shown in Table 1. In thecalculation, “Vienna Ab initio Simulation Package (VASP)” was used.

TABLE 1 Calculation program VASP Basis function plane-wave FunctionalGGA-PBE Pseudopotential PAW Cut-off energy 500 eV (optimization) 260 eV(classical molecular dynamics calculation) Number of grids at k-point 4× 4 × 3 (optimization) 1 × 1 × 1 (classical molecular dynamicscalculation) Ensemble NVT Temperature 2500 K Time interval (fs) 1.0Total calculation time (ps) 5.0

FIGS. 25A to 25D show calculation results. FIG. 25A shows an initialcrystal structure of an In—Ga—Zn oxide. FIG. 25B shows the crystalstructure of the In—Ga—Zn oxide after 5 picoseconds in which a hydrogenatom was not added, in the case where the temperature was set to 2500 K.FIG. 25C shows the crystal structure of the In—Ga—Zn oxide after 5picoseconds in which 4 hydrogen atoms (hydrogen concentration of 3.45atom %) were added, in the case where the temperature was set to 2500 K.FIG. 25D shows the crystal structure of the In—Ga—Zn oxide after 5picoseconds in which 8 hydrogen atoms (hydrogen concentration of 6.67atom %) were added, in the case where the temperature was set to 2500 K.

According to FIGS. 25A to 25D, the crystal structure of the structure inwhich hydrogen atoms were added is more disordered than that of thestructure in which a hydrogen atom was not added. This implies that thestrength of bonding in the In—Ga—Zn oxide becomes lower due to additionof hydrogen.

In order to quantitatively evaluate the effect of addition of hydrogenon the bonding strength in the In—Ga—Zn oxide, the radial distributionfunction was calculated only with In, Ga, Zn, and O, which are elementsother than hydrogen, in structures after 3 picoseconds to 5 picoseconds.The calculation results are shown in FIG. 26.

As shown in arrows in FIG. 26, a first peak gets lower and a valleybetween the first peak and a second peak gets shallower as a number ofadded hydrogen atoms is increased. Note that the radial distributionfunction g(r) is a function representing the probability density ofatoms existing at a distance of r from one atom. As the correlationbetween atoms becomes smaller, g(r) becomes closer to 1. Therefore, theresult of FIG. 26 shows that the bonding strength in the In—Ga—Zn oxidegets lower by addition of hydrogen and thus the structures are likely tobe broken (disordered).

As described above, when the concentration of an impurity (here,hydrogen) in the oxide semiconductor layer gets higher, the structure ofthe oxide semiconductor layer is disordered and crystallinity thereof islowered. Further, it can be said that an oxide semiconductor layerhaving an amorphous structure is a film containing a large amount of animpurity (here, hydrogen).

Example 3

In this example, results of comparison between oxide semiconductorlayers which differ in crystal state by various methods are described.

First, a method for manufacturing a measurement sample used in thisexample is described below.

<Measurement Sample A>

A CAAC-OS layer was used for a measurement sample A. In the measurementsample A, an oxide semiconductor layer was formed by a sputtering methodunder the following conditions: an In—Ga—Zn-oxide target (the atomicratio of In to Ga and Zn is 1:1:1) was used; an argon gas at a flow rateof 30 sccm and an oxygen gas at a flow rate of 15 sccm were used as adeposition gas; the pressure was 0.4 Pa; the substrate temperature was400° C.; and a direct-current (DC) power of 0.5 kW was supplied. Notethat a glass substrate was used as a substrate. Then, the oxidesemiconductor layer was heated at 450° C. in a nitrogen atmosphere forone hour and then heated at 450° C. in an oxygen atmosphere for onehour, whereby hydrogen contained in the first oxide semiconductor layerwas released and oxygen was supplied to the oxide semiconductor layer.The measurement sample A including the oxide semiconductor layer whichis a CAAC-OS layer was obtained in the above manner.

Note that the film density of the measurement sample A was measured tobe 6.3 g/cm³ by X-ray reflectometry (XRR). In other words, the CAAC-OSfilm is a film with a high film density.

<Measurement Samples B1 and B2>

A nanocrystalline oxide semiconductor layer was used for a measurementsample B1 and a measurement sample B2. In the measurement sample B1, anoxide semiconductor layer was formed by a sputtering method under thefollowing conditions: an In—Ga—Zn-oxide target (the atomic ratio of Into Ga and Zn is 1:1:1) was used; an argon gas at a flow rate of 30 sccmand an oxygen gas at a flow rate of 15 sccm were used as a depositiongas; the pressure was 0.4 Pa; the substrate temperature was roomtemperature; and a direct-current (DC) power of 0.5 kW was supplied.Note that a glass substrate was used as a substrate, and the measurementsample B1 including the oxide semiconductor layer which is ananocrystalline oxide semiconductor layer was obtained in the abovemanner.

The measurement sample B2 was formed as follows: an oxide semiconductorlayer which was formed in a manner similar to that of the oxidesemiconductor layer of the measurement sample B1 was heated at 450° C.in a nitrogen atmosphere for one hour and then further heated at 450° C.in an oxygen atmosphere for one hour as treatment for releasing hydrogencontained in the oxide semiconductor layer and then treatment forsupplying oxygen to the oxide semiconductor layer. The measurementsample B2 was obtained in the above manner.

Note that the film densities of the measurement samples B1 and B2 weremeasured by X-ray reflectometry (XRR). The film density of themeasurement sample B1 was 5.9 g/cm³, and the film density of themeasurement sample B2 was 6.1 g/cm³.

Thus, it is confirmed that the heat treatment can increase the filmdensity of the oxide semiconductor film.

<Measurement Sample C>

A nanocrystalline oxide semiconductor layer whose hydrogen content islarger than those in the measurement samples B1 and B2 was used for ameasurement sample C. As described in Example 2, the structure of theoxide semiconductor layer is disordered and crystallinity thereof islowered by addition of hydrogen to the oxide semiconductor layer. Thus,it can be said that the measurement sample C is a nanocrystalline oxidesemiconductor layer in which crystallinity is much lower than that ofthe measurement sample B1 and that of the measurement sample B2.

In the measurement sample C, the oxide semiconductor layer was formed bya sputtering method under the following conditions: an In—Ga—Zn-oxidetarget (the atomic ratio of In to Ga and Zn is 1:1:1) was used; a mixedgas of argon and hydrogen (Ar:H₂=14.8 sccm: 0.2 sccm) was used as adeposition gas; the pressure was 2.0 Pa; the substrate temperature wasroom temperature; and a direct-current (DC) power of 200 W was supplied.The measurement sample C was obtained in the above manner.

Note that the film density of the measurement sample C was measured byX-ray reflectometry (XRR). The film density of the measurement sample Cwas 5.0 g/cm³, and it is confirmed from this result that the filmdensity is lowered by addition of hydrogen.

FIGS. 27A to 27C show nanobeam electron diffraction patterns of themeasurement samples A, B1, and C which were obtained. FIGS. 27A, 27B,and 27C are nanobeam electron diffraction patterns of the measurementsample A, the measurement sample B1, and the measurement sample C,respectively. The nanobeam electron diffraction patterns in FIGS. 27A to27C were observed with the use of an electron beam whose diameter wasreduced to 1 nmφ.

In FIGS. 27A to 27C, there are the following findings. In themeasurement sample A which is a high-density CAAC-OS layer, spots arederived from crystallinity and arranged in an ordered manner. On theother hand, in the measurement sample C which is a low-densitynanocrystalline oxide semiconductor layer, although spots of electronbeams appear like spread halo pattern, nanocrystals remain partly. Inthe measurement sample B1 which is a medium-density nanocrystallineoxide semiconductor layer, spot-like patterns can be observed moreclearly.

Accordingly, the above results show that a film has higher crystallinityas the film density gets higher. In other words, it is shown that a filmhaving higher crystallinity can be obtained as the hydrogenconcentration gets lower.

Further, localized levels (defect states) of the obtained measurementsamples A, B1, and B2 were measured. Here, results of measuring thelocalized levels of the oxide semiconductor layers by constantphotocurrent method (CPM) are described.

In the CPM measurement, the amount of light with which a surface of themeasurement sample is irradiated is adjusted so that a photocurrentvalue is kept constant while voltage is applied between a pair ofelectrodes provided in contact with the oxide semiconductor layer, andthen an absorption coefficient was derived from the amount ofirradiation light in an intended wavelength range.

An absorption coefficient shown in FIG. 28 was obtained by removing anabsorption coefficient due to the band tail from the absorptioncoefficient obtained by the CPM measurement performed on the measurementsample A. That is, an absorption coefficient due to defects is shown inFIG. 28. An absorption coefficient shown in FIG. 29A was obtained byremoving an absorption coefficient due to the band tail from theabsorption coefficient obtained by the CPM measurement performed on themeasurement sample B1. That is, an absorption coefficient due to defectsis shown in FIG. 29A. An absorption coefficient shown in FIG. 29B wasobtained by removing an absorption coefficient due to the band tail fromthe absorption coefficient obtained by the CPM measurement performed onthe measurement sample B2. That is, an absorption coefficient due todefects is shown in FIG. 29B.

In FIG. 28 and FIGS. 29A and 29B, the horizontal axis indicates theabsorption coefficient, and the vertical axis indicates the photonenergy. The conduction band minimum energy and the valence band maximumenergy of the oxide semiconductor layer are set to 0 eV and 3.15 eV,respectively, on the vertical axis in FIG. 28 and FIGS. 29A and 29B.Each curve in FIG. 28 and FIGS. 29A and 29B represents a relationbetween the absorption coefficient and photon energy, which correspondsto defect states.

In the curve shown in FIG. 28, the absorption coefficient due to defectstates was 5.86×10⁻⁴/cm⁻¹. That is, the CAAC-OS film is a film with alow density of defect states where the absorption coefficient due todefect states is lower than 1×10⁻³ /cm, preferably lower than 1×10⁻⁴/cm.

FIG. 29A shows that, in the measurement sample B1, the absorptioncoefficient due to defect states was 5.28×10⁻¹ cm⁻¹. FIG. 29B showsthat, in the measurement sample B2, the absorption coefficient due todefect states was 1.75×10⁻² cm⁻¹. Thus, the heat treatment can reducethe number of defects in the oxide semiconductor layer.

According to the results obtained in the above manner, classification ofcrystal states of an oxide semiconductor (denoted by OS) is compared tosilicon (denoted by Si), which are shown in Table 2.

TABLE 2 Amorphous Microcrystal Polycrystal Continuous crystal Singlecrystal OS a-OS nc-OS Polycrystalline CAAC-OS Single crystal OS a-OS:Hμc-OS OS Nanobeam Halo Ring + Spot Spot Spot electron Spot diffractionCrystal part — nm-μm Discontinuous Continuously connected — DOS HighSlightly low — Low Extremely low Density Low Medium — High — Si a-Sinc-Si Polycrystalline CG silicon Single crystal Si a-Si:H μc-Si Si

As shown in Table 2, examples of oxide semiconductors having crystalstructures include an amorphous oxide semiconductor (a-OS and a-OS:H), amicrocrystalline oxide semiconductor (nc-OS and μc-OS), apolycrystalline oxide semiconductor (polycrystalline OS), a continuouscrystal oxide semiconductor (CAAC-OS), and a single crystal oxidesemiconductor (single crystal OS). Note that examples of the crystalstate of silicon include, as shown in Table 2, amorphous silicon (a-Siand a-Si:H), microcrystalline silicon (nc-Si and μc-Si), polycrystallinesilicon (polycrystalline Si), continuous crystal silicon (continuousgrain (CG) silicon), and single crystal silicon (single crystal Si).

When the oxide semiconductors in the above crystal states are subjectedto electron diffraction (nanobeam electron diffraction) using anelectron beam whose diameter is reduced to less than or equal to 10 nmφ,the following electron diffraction patterns (nanobeam electrondiffraction patterns) can be observed. A halo pattern (also referred toas a halo ring or a halo) is observed in the amorphous oxidesemiconductor. Spots and/or a ring pattern are/is observed in themicrocrystalline oxide semiconductor. Spots are observed in thepolycrystalline oxide semiconductor. Spots are observed in thecontinuous crystal oxide semiconductor. Spots are observed in the singlecrystal oxide semiconductor.

According to the nanobeam electron diffraction pattern, a crystal partin the microcrystalline oxide semiconductor has a diameter of nanometers(nm) to micrometers (μm). The polycrystalline oxide semiconductor hasdiscontinuous grain boundaries between crystal parts. No boundary isobserved between crystal parts in the continuous crystal oxidesemiconductor and the crystal parts are connected continuously.

The density of the oxide semiconductor in each crystal state isdescribed. The amorphous oxide semiconductor has a low density. Themicrocrystalline oxide semiconductor has a medium density. Thecontinuous crystal oxide semiconductor has a high density. That is, thedensity of the continuous crystal oxide semiconductor is higher thanthat of the microcrystalline oxide semiconductor, and the density of themicrocrystalline oxide semiconductor is higher than that of theamorphous oxide semiconductor.

A feature of density of states (DOS) existing in the oxide semiconductorin each crystal state is described. The DOS of the amorphous oxidesemiconductor is high. The DOS of the microcrystalline oxidesemiconductor is slightly low. The DOS of the continuous crystal oxidesemiconductor is low. The DOS of the single crystal oxide semiconductoris extremely low. That is, the DOS of the single crystal oxidesemiconductor is lower than that of the continuous crystal oxidesemiconductor, the DOS of the continuous crystal oxide semiconductor islower than that of the microcrystalline oxide semiconductor, and the DOSof the microcrystalline oxide semiconductor is lower than that of theamorphous oxide semiconductor.

The oxide semiconductor layer of one embodiment of the present inventionincludes a continuous crystalline oxide semiconductor with a low DOS asa channel which is a main current path, and includes a microcrystallineoxide semiconductor with a DOS lower than that of an amorphous oxidesemiconductor at the interface between an insulating layer and thechannel. Thus, a transistor including the oxide semiconductor layer canhave high reliability.

REFERENCE NUMERALS

102: insulating layer, 104: oxide semiconductor layer, 104 a: region,104 b: region, 106: insulating layer, 114: oxide semiconductor layer,114 a: region, 114 b: region, 124: oxide semiconductor layer, 124 a:region, 124 b: region, 124 c: region, 250: memory cell, 251: memory cellarray, 251 a: memory cell array, 251 b: memory cell array, 253:peripheral circuit, 254: capacitor, 260: transistor, 262: transistor,264: capacitor, 300: transistor, 301: substrate, 302: gate electrodelayer, 303: insulating layer, 304: oxide semiconductor layer, 304 a:oxide semiconductor layer, 304 b: oxide semiconductor layer, 305 a:source electrode layer, 305 b: drain electrode layer, 306: insulatinglayer, 307: insulating layer, 310: transistor, 314: oxide semiconductorlayer, 314 a: oxide semiconductor layer, 314 b: oxide semiconductorlayer, 316 a: source electrode layer, 316 b: drain electrode layer, 320:transistor, 324: oxide semiconductor layer, 324 a: oxide semiconductorlayer, 324 b: oxide semiconductor layer, 324 c: oxide semiconductorlayer, 350: transistor, 351: insulating layer, 352: insulating layer,360: transistor, 364: oxide semiconductor layer, 364 a: oxidesemiconductor layer, 364 b: oxide semiconductor layer, 364 c: oxidesemiconductor layer, 370: transistor, 402: insulating layer, 404: oxidesemiconductor layer, 404 a: oxide semiconductor layer, 404 b: oxidesemiconductor layer, 404 c: oxide semiconductor layer, 410: insulatinglayer, 500: substrate, 501: pixel portion, 502: scan line drivercircuit, 503: scan line driver circuit, 504: signal line driver circuit,510: capacitor wiring, 512: gate wiring, 513: gate wiring, 514: drainelectrode layer, 516: transistor, 517: transistor, 518: liquid crystalelement, 519: liquid crystal element, 520: pixel, 521: switchingtransistor, 522: driver transistor, 523: capacitor, 524: light-emittingelement, 525: signal line, 526: scan line, 527: power supply line, 528:common electrode, 801: transistor, 802: transistor, 803: transistor,804: transistor, 811: transistor, 812: transistor, 813: transistor, 814:transistor, 901: RF circuit, 902: analog baseband circuit, 903: digitalbaseband circuit, 904: battery, 905: power supply circuit, 906:application processor, 907: CPU, 908: DSP, 910: flash memory, 911:display controller, 912: memory circuit, 913: display, 914: displayportion, 915: source driver, 916: gate driver, 917: audio circuit, 918:keyboard, 919: touch sensor, 1000: sputtering target, 1001: ion, 1002:sputtered particle, 1003: deposition surface, 1021: main body, 1022:fixing portion, 1023: display portion, 1024: operation button, 1025:external memory slot, 1030: housing, 1031: housing, 1032: display panel,1033: speaker, 1034: microphone, 1035: operation key, 1036: pointingdevice, 1037: camera lens, 1038: external connection terminal, 1040:solar cell, 1041: external memory slot, 1050: television set, 1051:housing, 1052: storage medium recording and reproducing portion, 1053:display portion, 1054: external connection terminal, 1055: stand, 1056:external memory, 1101: main body, 1102: housing, 1103 a: displayportion, 1103 b: display portion, 1104: keyboard.

This application is based on Japanese Patent Application serial No.2012-288288 filed with the Japan Patent Office on Dec. 28, 2012, theentire contents of which are hereby incorporated by reference.

1. A semiconductor device comprising: an oxide semiconductor layer,wherein the oxide semiconductor layer comprises a first region and asecond region, wherein the first region has a crystal whose size is lessthan or equal to 10 nm, and wherein the second region has a crystal partwhose c-axis is aligned in a direction parallel to a normal vector of asurface of the oxide semiconductor layer.
 2. The semiconductor deviceaccording to claim 1, wherein the oxide semiconductor layer comprisesone of indium, gallium, and zinc.
 3. The semiconductor device accordingto claim 1, wherein oxide semiconductors included in each of the firstregion and the second region have different compositions from eachother.
 4. The semiconductor device according to claim 1, wherein, in thefirst region, circumferentially distributed spots are observed in ananobeam electron diffraction in which a diameter of an electron beam is1 nmφ or more and 10 nmφ or less.
 5. The semiconductor device accordingto claim 4, wherein, in the first region, wherein a halo pattern isobserved in a selected-area electron diffraction using a transmissionelectron microscope where a diameter of an electron beam is 300 nmφ ormore.
 6. The semiconductor device according to claim 1, wherein a filmdensity of the second region is higher than a film density of the firstregion.
 7. A semiconductor device comprising: an oxide semiconductorlayer; an insulating layer over the oxide semiconductor layer; a gateelectrode layer over the insulating layer, the gate electrode layeroverlapping with the oxide semiconductor layer; and a source electrodelayer and a drain electrode layer each electrically connected to theoxide semiconductor layer, wherein the oxide semiconductor layerincludes a first region and a second region, wherein the first regionhas a crystal whose size is less than or equal to 10 nm, wherein thesecond region has a crystal part whose c-axis is aligned in a directionparallel to a normal vector of a surface of the oxide semiconductorlayer, and wherein the first region is positioned between the insulatinglayer and the second region.
 8. The semiconductor device according toclaim 7, wherein the oxide semiconductor layer comprises one of indium,gallium, and zinc.
 9. The semiconductor device according to claim 7,wherein oxide semiconductors included in each of the first region andthe second region have different compositions from each other.
 10. Thesemiconductor device according to claim 7, wherein, in the first region,circumferentially distributed spots are observed in a nanobeam electrondiffraction in which a diameter of an electron beam is 1 nmφ or more and10 nmφ or less.
 11. The semiconductor device according to claim 10,wherein, in the first region, wherein a halo pattern is observed in aselected-area electron diffraction using a transmission electronmicroscope where a diameter of an electron beam is 300 nmφ or more. 12.The semiconductor device according to claim 7, wherein a film density ofthe second region is higher than a film density of the first region. 13.A semiconductor device comprising: a first insulating layer; an oxidesemiconductor layer over the first insulating layer; a second insulatinglayer over the oxide semiconductor layer; a gate electrode layer overthe second insulating layer, the gate electrode layer overlapping withthe oxide semiconductor layer; and a source electrode layer and a drainelectrode layer each electrically connected to the oxide semiconductorlayer, wherein the oxide semiconductor layer includes a first region, asecond region over the first region, and a third region over the secondregion, wherein each of the first region and the third region has acrystal whose size is less than or equal to 10 nm, and wherein thesecond region has a crystal part whose c-axis is aligned in a directionparallel to a normal vector of a surface of the oxide semiconductorlayer.
 14. The semiconductor device according to claim 13, wherein theoxide semiconductor layer comprises one of indium, gallium, and zinc.15. The semiconductor device according to claim 13, wherein oxidesemiconductors included in each of the first region and the secondregion have different compositions from each other, and wherein oxidesemiconductors included in each of the second region and the thirdregion each have different compositions from each other.
 16. Thesemiconductor device according to claim 13, wherein, in one of the firstregion and the third region, circumferentially distributed spots areobserved in a nanobeam electron diffraction in which a diameter of anelectron beam is 1 nmφ or more and 10 nmφ or less.
 17. The semiconductordevice according to claim 16, wherein, in one of the first region andthe third region, wherein a halo pattern is observed in a selected-areaelectron diffraction using a transmission electron microscope where adiameter of an electron beam is 300 nmφ or more.
 18. The semiconductordevice according to claim 13, wherein a film density of the secondregion is higher than a film density of one of the first region and thethird region.